How to Replace the Brakes on a 2005 Dodge Caravanby Chris Moore
Most 2005 model Dodge Caravans should have brake discs and calipers on all four wheels. The brake calipers on your van's wheels may be Teves or TRW calipers, particularly the front calipers. The type of calipers will make a slight difference in the process. Always change the brakes for both wheels on one end of the car together, but work on one brake assembly at a time.
Open the hood and siphon out about 2/3 of the brake fluid from the master cylinder with a syringe or similar tool. Discard the fluid as per your local ordinances.
Raise the van's front or rear end--whichever one you're changing the brakes on--and support it on jack stands. Remove the wheels. Block the wheels that are still on the ground.
Clean the entire brake assembly with an aerosol brake cleaner--never use compressed air. Use a drain pan to catch the residue.
Compress the caliper piston back into its bore with a C-clamp. Check the fluid level in the master cylinder as you compress the piston to make sure it doesn't overflow.
Removing the Old Pads
Pry off the anti-rattle spring clips from the caliper with a flat screwdriver. (This is only required for Teves calipers on the front brakes.)
Remove the guide pins or guide pin bolts for the caliper, lift it off the disc and hang it with a strong wire. Teves calipers have guide pins that require a hex wrench. TRW calipers have bolts that take a standard socket.
Pull out the outer and inner brake pads. The outer pads are always in the mounting bracket. The inner pads are clipped into the caliper piston bore on Teves calipers and within the mounting bracket on TRW calipers.
Installing the New Pads
Clean and inspect the guide pins, then lubricate them before installing them back in the caliper--use a high-temperature brake grease.
Apply an anti-squeal compound to the back of the new brake pads, applying the grease on the areas where they meet with the caliper and piston.
Install the brake pads in place on the caliper or mounting bracket, as appropriate. For inner brake pads on Teves calipers, seat the pad's retaining spring completely into the caliper piston bore.
Install the caliper back in place on the bracket. Tighten the guide pins/bolts to 26 foot-pounds.
Re-connect the wheels and lower the van after changing the brakes on both sides.
Fill the brake master cylinder with DOT Type 3 brake fluid until the reservoir is full.
Pump the brake pedal multiple times to properly seat the brakes.
Items you will need
- Syringe bottle
- Jack stands
- Lug wrench
- Brake cleaner
- Drain pan
- Flat screwdriver
- Socket wrench
- Hex socket (optional)
- Brake pads
- Brake grease
- Brake fluid
- "Chrysler Caravan/Voyager/Town & Country, 2003 through 2006 (Chilton's Total Car Care Repair Manual)"; John Wegmann; 2007
- Zedcor Wholly Owned/PhotoObjects.net/Getty Images