I have a 1999 Dakota extended cab with 5.2L engine, 4WD, and 5-speed manual. I bought it used in 2003 with around 92,000 miles. I just topped 240,000. It is my all-time favorite vehicle. There is, however, one serious issue. As many of you know, there is an ongoing problem with the front caliper bolts stripping their sockets in the knuckle; not surprising considering you have steel bolts in cast iron sockets. I have tried oversized bolts, helicoils, and inserts. They all work short-term. I am to the point where about every other time I do a front brake job I am forced to replace the knuckle. It is getting harder and harder to find used ones with good sockets. Is there anyone who still sells new ones? Or, is there anything else I can do?

 

If these are stripping out on you then you are not installing your front brakes correctly the key is to be sure your caliper pistons are 100% pushed in before installing the pins and new pads. If not pushed in 100% the pins will not Aline correctly and bind as you try to install them causing the pin holes to strip out.

Some times the pistons will start to pump back up on you as you try to install the caliper I find cracking the bleeder open at installation time prevents this pumping from accruing why the self pump happens I don't know but it happens.

Also these pins are not cranked down with a lot of force/torque all they are are guide pins about 20 LB of torque is all they need most people also think you need lock-tight on them but its not needed.

Easy to avoid if you install everything properly I know I went through this problem my fist time.

 

I always make sure the pistons are pushed in and the system is vented to equalize pressure. However, it did not occur to me to check the bolt torque. I will definitely install them with a torque wrench now. Thank you very much for the advice.

 

just double checked that and in the service manual its 22 LB of torque

One thing I also did was make sure the gide pin holes were 100% clean and dry fit the pins before I installed the calipers.

Those guide pin thread holes strip very easy thats for sure but taking extra time to be sure everything is good helps.