2002 Dodge Grand Caravan Brake Service (ONLINE REPAIR MANUALS)

Refer to. "Brake Pad Service" for caliper replacement procedures.

Front & Rear

Disassemble

• Remove caliper from adapter and rotor as outlined under. "Brake Pad Service.". Do not disconnect brake hose from caliper. Support caliper at all times to prevent brake hose damage.
• Position caliper away from rotor to prevent brake fluid spillage on machined surface, then place a small block of wood between caliper fingers to prevent piston damage during removal.
• Gently depress brake pedal to force caliper piston out of bore, then secure brake pedal at any position below one inch of pedal travel to ...

Manual

• Remove reservoir filler caps and fill reservoir with proper brake fluid.
• If calipers or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws.
• Close each bleed screw as fluid starts to drip from them.
• Fill master cylinder reservoir once more before proceeding.
• Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid,. Fig. . Ensure bleed hose is immersed in fluid.
• Open up bleeder, then have an assistant press down brake pedal.
• Once brake pedal is down, close bleeder. Repeat bleeding un...

• Raise and support vehicle, then remove wheel and caliper as outlined under. "Brake Pad Service.". Support caliper at all times ...

Height Sensing Proportioning Valve

1999-2000

• Raise and support vehicle, allowing rear suspension to hang free.
• Remove rear wheel and tire assemblies.
• Support rear axle.
• Disconnect track bar from rear axle, then the shock absorbers.
• Loosen, but do not remove, both leaf spring to front spring hanger pivot bolts.
• Loosen adjustment nut on actuator,. Fig. .
• Ensure hooked end of actuator is properly seated in clip on valve lever and clip is properly positioned on lever of valve.
• Pull housing of valve actuator toward spring hanger until lever on valve bottoms on body of valve. Hold valve actuator i...

Brake Lines & Linings

Remove one of the front wheels and inspect the brake disc, caliper and linings. The wheel bearings should be inspected at this time and repacked if necessary.

Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective pad is worn or damaged. Inspect and, if necessary, replace rear brake linings also.

If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.

Brake Roughness

The most common cause of brake chatter on disc brakes is a variation in thickness o...

Brake Drums

Any time the brake drums are removed for brake service, the braking surface diameter should be inspected with a suitable brake drum micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If the braking surface diameter exceeds specifications, the drum must be replaced. If the braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. Minor sc...