How to Change the Brake Pads in a 2002 Caravan

Calipers, pads and brake rotors are standard on front disc brakes, but rear disc brakes are becoming more popular.

The 2002 Dodge Caravan is a front-wheel drive minivan that features front disc brakes and rear drum brakes. This model is not to be confused with the Dodge Grand Caravan, which may feature all-wheel drive and rear disc brakes. In either case, replacing the front brake pads employs a similar procedure as the rear brake pads on the Grand Caravan models. The major difference between the front and rear pads is that the front pads are much larger as they account for 75 percent braking power for the minivan.

Things You'll Need

• Brake fluid syringe/siphon
• Tire wedge
• Tire iron
• Vehicle jack
• Jack stands
• Ratchet and socket set
• Screwdriver
• Large metal hook
• Caliper piston tool
• Wire brush
• Silicone brake grease
• Replacement pads
• Torque wrench
• DOT3 brake fluid

Instructions

1. Open the hood and remove the cover to the master cylinder. Remove at least half of the brake fluid from the master cylinder using a suitable brake fluid syringe or siphon. Discard the old fluid and then replace the cover to the master cylinder.

2. Apply the parking brake (in the event it's a Grand Caravan, do not apply the parking brake when replacing rear brake pads or you will not be able to get the calipers off), then place a tire wedge behind one of the rear tires.

3. Loosen the lug nuts on the front tires (or rear) with the tire iron. Do not turn the lug nuts more than half a turn.

4. Hoist the Caravan up with a jack and place it safely onto jack stands. Remove the lug nuts and then remove the wheels.

5. Remove the upper and lower caliper guide pin bolts using a ratchet and a socket.

6. Pry the caliper and pad assembly off of the rotor and knuckle adapter with a screwdriver. Hang the caliper onto the suspension spring so it does not stress the rubber brake hose.

7. Pry the retaining ears of the outboard brake pad off of the caliper housing. Use a caliper piston tool to compress the caliper piston. Use the face of the inboard pad as a bridge between the tool and the piston so no damage occurs to the piston. Compress the piston fully into the caliper bore and then remove the tool. Pull the inboard brake pad out from the caliper piston.

8. Use a wire brush to clean off any rust or corrosion on the knuckle adapter and caliper mating/sliding surfaces. Apply an even coating of silicone brake grease to the cleaned areas.

9. Install the replacement inboard pad into the caliper piston. Be sure the retaining clip and pad is fully seated in the piston. Install the outboard pad to the caliper. Use the screwdriver to help gently pry the ears of the new pads onto the outer caliper housing, if necessary.

10. Remove the caliper from the hook, then replace the caliper and brake pad assembly over the rotor and knuckle adapter. Replace the caliper guide pin bolts and tighten them to 35 foot-pounds with the torque wrench and a socket.

11. Replace the wheels and lug nuts after you've replaced the brakes on both the left and right side of the same (front or rear) axle. Snug the nuts to the rims with the tire iron (or ratchet and socket). Raise the Caravan with the jack to remove the jack stands and slowly lower it to the ground.

12. Torque the lug nuts in a crisscross manner with the torque wrench set at 100 foot-pounds and a suitable size socket (3/4 inch or 19 mm).

13. Apply the brake pedal several times until it feels firm. Check the brake fluid level in the master cylinder and top it off with DOT3 brake fluid if necessary.

14. Remove the tire wedge, release the parking brake and test drive the Caravan for braking performance.

References

• Car Tuning Central: How to Change Brake Pads