Step-by-Step Instructions for a Brake Rotor Replacement on a 2005 Dodge Grand Caravan

A properly maintained braking system is essential for the safety of you, your passengers and others on the road. A wearing part on your 2005 Dodge Grand Caravan, brake rotors need to be checked regularly to ensure that they are in good working order, and must be replaced prior to the possibility of failure. With the correct tools and care a mechanically inclined person can replace their own brake rotors, saving on labor costs that would be spent at an auto repair shop.

Instructions

1

Park your Dodge Grand Caravan on a level surface and activate the parking brake. Place blocks behind the rear wheels to prevent the van from rolling.

2

Use the lug wrench to loosen the lug nuts on the front wheels a single turn. This makes it easier to get them off when the tires are off the ground.

3

Jack up the front of the van until the front wheels are no longer touching the ground. Place jack stands under the frame and lower your Caravan gently onto them.

4

Remove the lug nuts and slide the wheels off. Set them aside. Be careful not to lose the lug nuts.

5

Remove the two mounting bolts that secure the disk brake caliper to the steering knuckle. On some models these require a standard wrench or socket, while on others you will use a 7mm Allen wrench. Slide the bolts out, making note if one is longer than the other, and their placement.

6

Slide the disk brake caliper off of the brake rotor and hang it out of the way with a wire or bungee cord. Use caution not to drop the caliper or hang it by the brake line. A damaged brake line will result in total loss of braking power.

7

Remove retaining clips from wheel studs, if present. Pry these off with a flat head screwdriver.

8

Pull the brake rotor off of the wheel studs. They can become stuck over time. Use a pry bar or hammer to get them of if necessary. You will not be reusing these rotors; damaging them is not an issue.

9

Slide the new brake rotors on to the wheel studs and replace retaining clips. Do not hammer or drop the new rotors, as they may warp and cause braking problems on your van.

10

Slide the brake caliper on the new brake rotor, aligning the bolt holes on the caliper with the bolt holes on the steering knuckle. Screw in the caliper mounting bolts in by hand, and then tighten them with a wrench or socket.

11

Reinstall front wheels and tighten lug nuts in a crisscross pattern.