The Dodge Caravan, Grand Caravan, Plymouth Voyager, Grand Voyager and Chrysler Town and Country all employ the same braking systems. The parts may be slightly different between the regular Caravan and Grand Caravan to support the extra weight of the vehicle. While all these minivans feature front disc brakes, most commonly they use rear drum brakes. However, later models of the all-wheel drive Grand Caravans may feature rear disc brakes. The caliper and pads are much smaller and located at the top of the rotor. To replace either front or rear pads employs the same procedure.
Loosen the lug nuts slightly before lifting the Grand Caravan. If applicable, remove the hubcaps first. Lift and support the Grand Caravan with a jack and jack stand. Do not place the jack stand onto the rocker panel or it may collapse. Place it under the engine mount or on the front frame rail. Remove the lug nuts with the socket wrench and then remove the tires.
Remove the upper and lower caliper bolts. Identify if the Grand Caravan uses different-sized bolts to replace them correctly. Set the bolts aside.
Wiggle the caliper and pad assembly off of the rotor. Support the caliper to the strut spring to prevent damage to the brake hose. Remove the outboard pad using a screwdriver to pry off the retaining tabs from the caliper housing. Pull the inboard pad spring clip out of the caliper piston.
Compress the caliper piston using a C-clamp and one of the old pads braced up against the caliper piston. Tighten the C-clamp slowly until it is fully compressed.
Clean the caliper mating surface of the caliper adapter where the pad tabs and caliper housing sit against. Apply a light coat of silicone lubricant to the cleaned surface area. Inspect the rotor for any visual damage such as scoring or rust pits. If necessary, replace the rotors.
Install the inboard pad and spring clip retainer into the caliper piston and then install the outboard pad to the caliper housing. Be sure the retaining clips are properly holding the pad in the correct position. Place the caliper and pad assembly over the rotor. Make sure the brake hose is not twisted. Apply a light coat of lubricant to the unthreaded section of the caliper bolts. Align the caliper correctly and then install the bolts and tighten them.
Replace the wheel and lug nuts. Tighten the lug nuts to 100-foot pounds with a toque wrench and a 19mm socket. Pump the brake pedal four to five times to seat the pads to the rotor and prevent the master cylinder from overflowing before doing the other side brake pads.
Repeat steps 1 through 7 for the other side. Check the master cylinder fluid level and add brake fluid if necessary. Test-drive the Grand Caravan.
