How to Install Brakes in a Dodge Caravan

Installing brakes in your Dodge Caravan is a difficult job. You are dealing with one of the most important safety components of your vehicle. If you choose to install new brakes yourself (professional installation is always recommended), the process can vary depending on the type of brake calipers your van uses. Look to the type of bolts the caliper has to determine this.

Instructions

Removing Old Brakes

1

Siphon at least two thirds of the brake fluid from the brake master cylinder using a syringe or similar tool. Dispose of the fluid as per your local ordinances.

2

Raise the end of the van, front or back, depending on which brakes you are installing and support the van on jack stands. Remove the wheels on both sides.

3

Clean the entire surface of the brake assembly with an aerosol brake cleaner, placing a drain pan underneath to catch the residue. Never use compressed air.

4

Compress the caliper's piston into its bore with a C-clamp; if you are replacing the caliper, this isn't needed. Watch the fluid level in the master cylinder as you compress the piston. Make sure it doesn't overflow.

5

Remove the brake calipers by removing their mounting bolts; depending on the type of calipers, these can require a socket or hex wrench. If the caliper uses hex bolts, it also has anti-rattle clips that you must pry off with a flat screwdriver.

6

Hang the caliper from the van's shock absorber spring with strong wire, or rest it on the leaf spring; don't let it hang by the hose. Disconnect the caliper from the hoseremove the banjo boltonly if you're replacing the caliper.

7

Pull out the brake pads. The outer pads are always in the caliper mounting bracket. If the caliper uses hex bolts, the inner pad is in the caliper; if the caliper uses regular bolts, the inner pad is in the mounting bracket.

Installation

8

Remove, clean and re-install the anti-rattle clips in the caliper mounting bracket. Do the same with the guide pins and lubricate them with a high-temperature brake grease.

9

Apply anti-squeal compound to the backing plates of the new brake pads, then install them. If the brakes use calipers that require hex bolts, the inner brake pad goes into the caliper with its retaining spring seated into the piston bore. All other pads go into the mounting bracket.

10

Mount the caliper onto its mounting bracket; if it's a replacement caliper, connect it to the brake hose using the banjo bolts. Tighten the caliper mounting bolts to 125 foot-poundsthis is the case for both types of bolts.

11

Reconnect the wheels and lower the van once you've installed the brakes on both sides. If you changed a brake caliper, do not do this or the following steps until you bleed the brakes (see Section 3).

12

Add brake fluid to the master cylinder reservoir until it is full. Use DOT Type 3 fluid.

13

Set the brakes by pumping the pedal multiple times.

Bleeding the Brakes

14

Fill the brake master cylinder reservoir with DOT Type 3 brake fluid and close the reservoir.

15

Place a length of clear tubing over the bleeder valve for the caliper you installed. Place the tube's other end into a container partially filled with brake fluid.

16

Open the bleeder valve while another person pushes on the brake pedal; open it just enough to let a flow of fluid leave the valve and look for air bubbles in the container. Close the valve and have the assistant release the pedal once the flow slows down.

17

Repeat the previous step until there are no more air bubbles, then close the valve and remove the tube.