How to Fix the Brake Pads on a 2002 Grand Caravan

The 2002 Dodge Grand Caravan always employs front disc brakes and pads, as do all vehicles nowadays. However, it may feature rear disc brakes on some all-wheel drive models or it may feature rear drum brakes on front-wheel drive models. While the illustrated procedure demonstrates how to fix the front brake pads, the content can also be used when replacing rear brake pads with some minor differences. Keep in mind the rear pads are smaller and only account for about 30 percent braking capacity for the minivan.

Instructions

1

Park the Grand Caravan on a level, hard surface suitable for lifting and supporting the vehicle. Apply the parking brake (only if fixing the front brake pads) and then release the primary hood release from inside the minivan.

2

Place a wheel wedge (or block of wood) behind one of the rear tires (or in front of one of the front tires if fixing the rear pads) and then open the hood.

3

Suck out half of the brake fluid in the master cylinder with a brake fluid suction device and then replace the cap to the master cylinder. Replace the cap securely.

4

Break the lug nuts loose (on the axle you're fixing the brake pads) with a tire iron wrench by turning them 1/4-turn counterclockwise (only).

5

Raise the Grand Caravan with a hydraulic jack (one side at a time) and then lower it onto jack stands strategically placed beneath the engine bracket. Keep in mind if you use the rocker panels on a Caravan they may collapse under the weight of the vehicle.

6

Finish removing the lug nuts and then remove the wheels.

7

Remove the upper and lower caliper guide pin bolts with a box wrench.

8

Pry the caliper off of the caliper bracket and rotor using a small pry tool and then wrap heavy-duty wire through the caliper and use the wire to hang it from the front coil spring so it does not dangle from the hydraulic brake hose.

9

Pry the outboard pad retaining clip over the raised area of the caliper housing using the small pry bar in order to slide the outboard pad down off of the caliper.

10

Pull the inboard pad away from the caliper piston until the pad's retaining clip unseats from inside the caliper piston cavity.

11

Compress the caliper piston using a C-clamp and a suitable piece of wood to anchor against the piston in order to prevent damage from occurring to the piston while driving it into its bore with the clamp.

12

Replace the replacement inboard pad first by pushing its retaining clip into the caliper piston cavity and then attach the outboard pad and retaining clip.

13

Remove the wire from the caliper and then replace it over the rotor and bracket. Align the guide pin bolts and insert them into their respective holes. Tighten the bolts to 35-foot pounds with a torque wrench and socket.

14

Complete the pad replacement for the other side before replacing the wheels and lug nuts. Tighten the lug nuts as tight to the hub as possible with the axle raised. Lower the Grand Caravan to the ground (by reversing the lifting procedure) and then tighten the lug nuts with the torque wrench to 100-foot pounds with a suitable sized socket. Use a crisscross pattern when torquing the lug nuts.

15

Pump the foot brake pedal several times until the pedal feels firm and normal. Re-check the master cylinder brake fluid level and add brake fluid if necessary.