GrandCaravan 2008

Brake Calipers

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the battery negative cable from the battery post.
  4.  
  5. Using a brake pedal holding tool, depress the brake pedal past its first inch of travel and hold it in this position. Holding the pedal in this position will isolate the master cylinder from the hydraulic brake system and will not allow the brake fluid to drain out of the brake fluid reservoir while the brake lines are open.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the wheel and tire assembly.
  10.  
  11. Manually release the automatic self-adjusting mechanism tension of the parking brake lever assembly.
  12.  
  13. Collapse the cable retainer fingers at the end of the cable housing, then pull the cable housing out of the mounting bracket.
  14.  
  15. Slide the cable strand out of the mounting bracket, then pull the parking brake cable strand upward and unhook it from the caliper lever.
  16.  
  17. Remove the banjo bolt (3) connecting the brake flex hose (2) to the brake caliper (1).
    NOTE
    There are 2 washers that will come off with the banjo bolt. Discard the washers. They should not be reused.


    NOTE
    When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head.

  18.  
  19. Remove the 2 caliper guide pin bolts.
  20.  
  21. Slide the disc brake caliper from the disc brake adapter bracket and brake pads.

    Click image to see an enlarged view

    Fig. Removing the rear brake caliper and brake hose

  22.  

To install:


NOTE
When installing a new brake caliper, it is necessary to bleed the brakes.

  1. Remove the outboard pad from the adapter bracket.
    WARNING
    Use care when installing the caliper onto the adapter bracket to avoid damaging the guide pin boots.

  2.  
  3. Install the disc brake caliper over the inboard brake pad on the brake caliper adapter bracket and the brake rotor.
    NOTE
    When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head.

  4.  
  5. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper and lower caliper guide pin bolts. Lightly tighten the guide pin bolts at this time.
  6.  
  7. Install the banjo bolt (3) connecting the brake flex hose (2) to the brake caliper (1). Be sure to install a NEW brake hose washer on each side of the hose fitting as the banjo bolt is guided through the fitting.
  8.  
  9. Thread the banjo bolt into the caliper and tighten it to 18 ft. lbs. (24 Nm).
  10.  
  11. If removed, install the caliper lever return spring (1) between the cable lever (2) and the anchor bracket (3). Do not reconnect cable equalizer at this time.

    Click image to see an enlarged view

    Fig. If removed, install the caliper lever return spring (1) between the cable lever (2) and the anchor bracket (3)

  12.  
  13. Access the interior of the vehicle, remove the brake pedal holder, then slowly pump the brake pedal until the rear caliper fingers touch the outboard surface of the brake rotor where the brake pad was removed. Release the pedal.
  14.  
  15. Remove the brake caliper lower guide pin bolt.
  16.  
  17. Swing the caliper assembly upward, pivoting off the upper guide pin, until clear of the adapter bracket.
  18.  
  19. Reinstall the outboard pad in the adapter bracket.
  20.  
  21. Open the caliper bleeder screw at least one full turn.
  22.  
  23. Seat (bottom) the caliper piston in the bore as follows:
    1. Assemble a 3 / 8 inch drive ratchet handle and an extension (3).
    2.  
    3. Insert the extension through Special Tool 8807-1 (2).
    4.  
    5. Place Special Tool 8807-2 (1) on the end of the extension.
    6.  
    7. Insert the lugs on Special Tool 8807-2 into the notches in the face of the caliper piston (5).
    8.  
    9. Thread the screw drive on Special Tool 8807-1 down until it contacts the top of Special Tool 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur.
    10.  
    11. Turn Special Tool 8807-2 with the ratchet, rotating the piston in a clockwise direction until it is fully seated (bottomed) in the bore. It may be necessary to turn Special Tool 8807-1 with Special Tool 8807-2 to start the process of piston retraction.

      Click image to see an enlarged view

      Fig. Seat (bottom) the caliper piston in the bore using Special Tools 8807-1/8807-2

    12.  

  24.  
  25. Close the bleeder screw.
    WARNING
    Use care when installing the caliper onto the adapter bracket to avoid damaging the guide pin boots.

  26.  
  27. Return the brake caliper back down over the adapter bracket into the mounted position and install the lower guide pin bolt and lightly tighten.
    NOTE
    While bleeding air from the brake caliper in the following steps, be sure to monitor the fluid level in the master cylinder reservoir making sure it does not go dry.

  28.  
  29. Have a helper pump the brake pedal 3-4 times and hold it in the down position.
  30.  
  31. With the pedal in the down position, open the bleeder screw at least 1 full turn and let out the fluid and air, if any is present.
  32.  
  33. Once the brake pedal has dropped, close the bleeder screw. Once the bleeder screw is closed, release the brake pedal.
  34.  
  35. Repeat the previous 3 steps as necessary until all the trapped air is removed.
  36.  
  37. If necessary, bleed the remaining wheel circuits using the normal bleeding procedure.
  38.  
  39. Tighten both guide pin bolts to 26 ft. lbs. (35 Nm).
  40.  
  41. Pull the parking brake cable strand outward from the cable housing and hook it onto the caliper lever.
  42.  
  43. Push the excess cable strand back into the cable housing, then insert the cable housing (3) into the mounting bracket (1) until the retainer fingers (2) lock into place. Make sure both fingers are engaged preventing removal of the cable from the bracket.

    Click image to see an enlarged view

    Fig. Insert the cable housing (3) into the mounting bracket (1) until the retainer fingers (2) lock into place

  44.  
  45. Reconnect the parking brake cable equalizer and reset the automatic self-adjusting mechanism tension of the parking brake lever assembly.
  46.  
  47. Install the tire and wheel assembly and tighten the wheel mounting nuts to 100 ft. lbs. (135 Nm).
  48.  
  49. Lower the vehicle.
  50.  
  51. Connect the battery negative (-) cable to the battery post.
  52.  
  53. Road test the vehicle making several stops to wear off any foreign material on the brakes and to seat the brake pads.
  54.  

 
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