How to Replace a Caliper in a Dodge Caravan

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Changing or replacing a brake caliper is no small task, especially for a vehicle as large as a Dodge Caravan. Consult with a mechanic or expert before taking on such an important task. Replacing a caliper on a Caravan or any vehicle is often best left in the hands of a professional.

Things You'll Need

  • Allen wrench
  • Tire iron
  • Jack
  • Oil/fluid pan
  • Caliper for Caravan
  • Copper washers
  • Transparent hose

Remove the Old Caliper

  • Raise and support the van, making sure you use a jack for a vehicle of its size. Remove the wheel.

  • Disconnect the brake hose from the caliper by removing the attaching bolt. Discard the seal washers. Plug the hose to prevent fluid from leaking.

  • Remove the caliper guide pin bolts. Slide the caliper slowly away from the steering knuckle. Slide the caliper's opposite end out from under the machined abutment on the steering knuckle.

  • Clean the steering knuckle abutment surfaces of any grease, dirt or corrosion. Spray a fine mist of water on the surface and use a damp rag for this. Lubricate the abutment surfaces with a liberal amount of multipurpose lubricant.

Install the New Caliper

  • Position the new caliper over the brake pads and disc rotor. Be careful not to damage the caliper seals or guide pin bushings from the steering knuckle bosses while installing.

  • Reinstall the caliper guide pin bolts. Make sure you don't cross thread them. Torque the front caliper bolts to 195 inch pounds. Torque the rear caliper bolts to 192 inch pounds.

  • Attach the brake hose to the caliper with new washers. Tighten the bolt to 35 foot pounds.

  • Bleed the brake system. Open the bleeder valve on the assembly, attach a transparent hose to it and press on the brake pedal to remove air from the system.

  • Place the wheel back on the vehicle and torque the lug nuts to 100 foot pounds. Lower the van and pump the brake pedal several times to insure firmness. Then test drive the van.

Tips & Warnings

  • Do not dry clean any brake parts because they may contain asbestos fibers. Dispose any cloths you use on them into an airtight container.

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