2005 Dodge Grand Caravan Brake Service (ONLINE REPAIR MANUALS)

Caravan, Town & Country & Voyager

Front

Removal

• Raise and support vehicle.
• Remove front wheel and tire assemblies.
• Remove two caliper-to-knuckle attaching bolts, then remove caliper by sliding away from adapter and lifting off rotor, Fig. . Support caliper firmly to prevent weight of caliper from damaging flexible hose.
• Remove outboard pad by prying pad retaining clip over raised area of caliper, then sliding pad down and off of caliper.
• Pull inboard pad away from caliper piston, until springs release from piston.

Installation

• Inspect piston seal for leaks and for ruptures in piston du...

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 unt...

Caravan, Town & Country & Voyager

Park Brake Shoes

• Set parking brake. Parking brake is set to keep hub/bearing and axle shaft from rotating when loosening hub nut.
• Raise and support vehicle allowing rear suspension to hang free.
• Remove rear wheels.
• Remove cotter pin and nut retainer from stub shaft of outer C/V joint.
• Remove spring washer, hub nut and washer from stub shaft of outer C/V joint.
• Release parking brake.
• Create slack in rear park brake by locking out automatic adjuster as follows:
• Grasp exposed section of front park brake and pull downward on it.
• Install a pair of suitab...

Pedal Falls Away

• System leak at brake line, fitting, hose or caliper/wheel cylinder.
• Internal leakage in master cylinder caused by worn or damaged piston cups.
• Internal leak in ABS or RWAL system.

Low Pedal

• Worn brake linings.
• Worn drums or rotors.
• Rear brakes out of adjustment.

Spongy Pedal

• Air in hydraulic system.
• Thin brake drums.
• Substandard brake lines and hoses.

Hard Pedal Or High Pedal Effort

• Linings that are water soaked, contaminated or glazed.
• Faulty power booster or check valve.

Pedal Pulsation

• Disc brake rotors have excessive lateral runout or thickness variation.
• Out of round brake ...

Pedal Falls Away

• System leak at brake line, fitting, hose or caliper/wheel cylinder.
• Internal leakage in master cylinder caused by worn or damaged piston cups.
• Internal leak in ABS or RWAL system.

Low Pedal

• Worn brake linings.
• Worn drums or rotors.
• Rear brakes out of adjustment.

Spongy Pedal

• Air in hydraulic system.
• Thin brake drums.
• Substandard brake lines and hoses.

Hard Pedal Or High Pedal Effort

• Linings that are water soaked, contaminated or glazed.
• Faulty power booster or check valve.

Pedal Pulsation

• Disc brake rotors have excessive lateral runout or thickness variation.
• Out of round brake ...

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 required.

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 required, 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 of ...