2005 Dodge Grand Caravan Rear Disc Brake Rotor Removal

by Jody L. Campbell

By 2005, the Dodge Grand Caravan had replaced its smaller counterpart, the Caravan. It most commonly featured both front and rear disc brakes. While both front and rear disc brakes are very similar to replace, the rear disc brake rotors on the Grand Caravan use the protruding hub as a brake drum to cover the parking brake shoes. These shoes work similarly to drum brakes, but only when the parking brake is applied. To successfully extract the rotor without damaging the parking brake shoe assembly, a little more skill is required.

Place a wheel block in front of one of the front tires of the Grand Caravan on a level, hard surface. Assure the parking brake is not engaged.

Crack the lug nuts loose using the lug wrench prior to lifting the rear tire or tires.

Lift the rear of the minivan with the jack and support it safely onto a jack stand. If you're doing both sides, repeat this step for the other side. Finish removing the lug nuts and wheels once the rear of the van is raised.

Place the small pry bar into the pads window of the caliper (located on top of the rear brake assembly). Pivot the pry bar between the outboard pad backing plate and against the rotor to compress the caliper piston enough to allow movement of the caliper back and forth. Do not over compress or you will damage the outboard pad retaining spring.

Remove the front and rear caliper guide bolts with the 7 mm hex-head wrench or bit with ratchet assembly. Pull the caliper and brake pad assembly up off the rotor and stick it behind the backing plate so no damage will come to the brake hose.

Spray a generous amount of lubricant spray on the junction of the center rotor hole and the hub face. Allow five minutes or so for the lubricant to penetrate.

Set up the drum and rotor pulling tool so the three teeth grab the inside edge of the rotor in a triangular pattern. Place the center of the puller against the hub facing and tighten the handle clockwise to slowly pull the rotor off the hub and parking brake shoe assembly until the rotor breaks free.

Remove the puller and then remove the rotor.

Tips

  • check It is not uncommon for the parking brake shoes to separate from the backing plate and require replacement.
  • check If replacing the rotor, you can use a hammer and pry tool to remove the rotor in place of the puller tool, but there's a greater chance of damaging the parking brake shoes.

Warnings

  • close If the rotor (and pads) are being replaced, you will need to fully compress the caliper piston inward. A large C-clamp will work nicely, but remove the outboard pad retaining spring first so you do not bend it.
  • close Once caliper pistons have been compressed and before test-driving the vehicle, you need to pump the brake pedal several times until it feels firm. Otherwise you will not have a working brake pedal and this can cause an accident.

Items you will need

About the Author

Jody L. Campbell spent over 15 years as both a manager and an under-car specialist in the automotive repair industry. Prior to that, he managed two different restaurants for over 15 years. Campbell began his professional writing career in 2004 with the publication of his first book.

Photo Credits

  • photo_camera disque de frein image by Christophe Fouquin from Fotolia.com