How to Replace a Caliper in a Plymouth Voyager

If you need to replace parts like a brake caliper in a Plymouth Voyager, you might need to check parts for the Chrysler minivan under the same name. Make sure any replacement parts come from a reputable source and they will work on your Plymouth machine.

Instructions

Remove the Old Caliper

1

Lift the front end of the van securely on a jack stand and remove the wheels. The Plymouth Voyager only has calipers on the front brakes, since it uses drum brakes on the rear axle.

2

Unscrew the attaching bolt on the brake hose to disconnect it from the caliper. Plug up the line with a small piece of rubber. Toss out the copper washers, as you will need to use new ones upon assembly.

3

Disconnect the caliper guide pin bolts securing the caliper to the steering knuckle. Slide the caliper slowly away from the knuckle. Slide the caliper's opposite end out from under the knuckle's machined abutment.

4

Clean the abutment surfaces and lubricate them multipurpose lubricant. Run a mist of water over the surface and use a damp rag to clean them. Never dry clean brake parts because of asbestos risk.

Install the Replacement Caliper

5

Place the replacement caliper over the brake pads and rotor. Make sure you don't damage the caliper seals or guide pin bushings from the steering knuckle bosses.

6

Install the guide pin bolts and the brake hose to the caliper. Use new washers with the brake hose's fitting bolt.

7

Fill the brake master cylinder with fluid. Connect the brake bleeder valve to a container of fluid with a rubber hose and have another person remove air from the system by using the brake pedal.

8

Install the wheels back on the van. Attach the lug nuts to half their full torque before lowering the van, then finish tightening them.

9

Set the brake pads. Pump the pedal until it feels firm. Test the brakes out on the road.