How to Change the Brake Pads on a 2002 Chrysler Van

The 2002 Chrysler vans were among the first models to use different types of calipers. Your van may use Teves or TRW calipers, which can make the process of changing brakes slightly different depending on the type. This can apply to any 2002 model minivan, including the Caravan, Town and Country or Voyager. Check with your mechanic before you try working on the brakes yourself.

Instructions

1

Loosen the lug nuts on the front or rear wheels--whichever end you are changing the pads on. Raise that end of the van and support it on jack stands. Apply the parking brake and remove the wheels.

2

Siphon out 2/3 of the brake fluid from the master cylinder reservoir using a syringe, a vacuum pump or a turkey baster; make sure the siphon tool hasn't been used for anything before. Discard the fluid as per your local laws.

3

Clean off the brake assemblies with aerosol brake cleaner. Use a drip pan to catch the residue and dispose of it properly.

4

Compress the caliper piston into the bore with a C-clamp. This will cause fluid to enter the master cylinder; make sure it doesn't overflow and siphon out more if needed.

5

Disconnect the brake caliper from the disc by removing the anti-rattle spring with a flat screwdriver and the caliper's guide pin bolts. TRW calipers use bolts requiring a standard socket wrench, while Teves caliper bolts require a hex socket.

6

Remove the brake pads from the caliper bracket if the brakes use TRW calipers. On Teves calipers, remove the outer pad from the bracket and the inner one from the caliper; the inner pad is connected to the piston bore through a retaining spring.

7

Hang the caliper by the strut spring with a strong wire while you prepare the new brake pads. Never let the caliper hang by the brake hose.

Installing New Pads

8

Remove the guide pin bushings, inspect them for damage and replace them if needed. Lubricate the bushings with multipurpose grease and install them.

9

Apply anti-squeal compound to the back of the brake pads in the areas where they come in contact with the caliper and piston.

10

Install both brake pads onto the caliper bracket and anti-rattle clips for TRW calipers. On Teves calipers, install the inner pad into the caliper and fully seat it into the piston bore, then install the outer pad into the bracket.

11

Reconnect the caliper onto the steering knuckle and tighten the bolts to 35 ft. lbs. Install the anti-rattle spring, hooking the end over the caliper's bracket tab.

12

Reconnect the wheels and lower the car once you've changed the pads on both brakes.

13

Pump the brake pedal multiple times to seat the brake pads.