🔧 Town & Country - Front Brake Pads & Rotor Replacement

You’ll remove the front wheels, unbolt the brake calipers and brackets, replace the rotors, and install new pads. Worn pads or warped rotors can cause squealing, grinding, vibration, and longer stopping distances.

Difficulty Level: Intermediate | Estimated Time: 2-4 hours

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⚠️ Safety & Precautions

• 🧯 Work on level ground and support the van with jack stands, not just a jack.
• 🧤 Brake dust is irritating—wear nitrile gloves and a dust mask; use brake cleaner, not compressed air.
• 🔥 Brakes get hot—let everything cool before starting.
• 🪝 Never let the caliper hang by the brake hose—support it with a bungee cord.
• 🔋 Battery disconnect is not required for this job.

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🔧 Required Tools

You'll need the following tools for this repair:

• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• Wheel chocks
• Lug wrench or 19mm socket
• Ratchet 3/8"
• Ratchet 1/2"
• Torque wrench 3/8"
• Torque wrench 1/2"
• 13mm socket
• 21mm socket
• Breaker bar 1/2"
• C-clamp 6 inch
• Flathead screwdriver
• Wire brush
• Bungee cord
• Brake parts cleaner
• Shop rags
• Safety glasses
• Nitrile gloves
• Dust mask

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Front brake pad set - Qty: 1
• Front brake rotors - Qty: 2
• Front brake hardware kit - Qty: 1
• Brake lubricant - Qty: 1
• Brake fluid DOT 3 - Qty: 1 quart

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📋 Before You Begin

• 🅿️ Park on level ground, shift to Park, and set the parking brake.
• 🧱 Chock the rear wheels with wheel chocks.
• 🧴 Pop the hood and locate the brake fluid reservoir; keep the cap loosely on to prevent splashes.
• 🧻 Place rags under the reservoir area in case fluid rises when you compress the pistons.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Loosen the front wheel lug nuts

• Use a lug wrench or 19mm socket to loosen the lug nuts about 1/2 turn while the tires are still on the ground.

Step 2: Lift and support the front end

• Use a floor jack (rated 3-ton minimum) to lift the front of your Town & Country at the approved front jacking point.
• Set it down securely on jack stands (rated 3-ton minimum).
• Shake test it before working underneath.

Step 3: Remove the front wheels

• Use a lug wrench or 19mm socket to remove the lug nuts, then remove both front wheels.

Step 4: Remove the caliper guide pin bolts

• Turn the steering wheel for better access (left for right side work, right for left side work).
• Use a 13mm socket and ratchet 3/8" to remove the two caliper guide pin bolts.
• Lift the caliper off the bracket and support it with a bungee cord.
• Torque spec (install later): Torque to 35 Nm (26 ft-lbs)

Step 5: Remove the old pads and hardware

• Pull the old pads out by hand.
• Use a flathead screwdriver to pop the old stainless pad clips out of the bracket.

Step 6: Remove the caliper bracket

• Use a 21mm socket, breaker bar 1/2", and ratchet 1/2" to remove the two caliper bracket bolts.
• Remove the bracket and set it aside.
• Torque spec (install later): Torque to 169 Nm (125 ft-lbs)

Step 7: Remove the rotor

• Pull the rotor straight off the hub.
• If it’s stuck from rust, spray the hub area with brake parts cleaner, then tap the rotor hat firmly (not the thin braking surface) and work it off.

Step 8: Clean the hub face

• Use a wire brush to clean rust off the hub face where the rotor sits.
• Wipe clean with shop rags and a quick spray of brake parts cleaner.
• A clean hub helps prevent brake pedal vibration.

Step 9: Install the new rotor

• Spray both sides of the new rotor with brake parts cleaner and wipe with shop rags to remove packing oil.
• Slide the new rotor onto the hub.
• To keep it from wobbling while you work, hand-thread 1-2 lug nuts on backwards a few turns (use your fingers only).

Step 10: Prep the caliper bracket and install new hardware

• Install the new stainless hardware clips from the front brake hardware kit into the bracket by hand.
• Use a wire brush to clean the bracket pad “shelves” where the clips sit.
• Apply a thin film of brake lubricant where the pad ears contact the clips.

Step 11: Reinstall the caliper bracket

• Position the bracket over the new rotor.
• Thread the bracket bolts in by hand first, then tighten using a 21mm socket and ratchet 1/2".
• Final tighten with a torque wrench 1/2" (a torque wrench is a tool that tightens bolts to an exact safe setting).
• Torque to 169 Nm (125 ft-lbs)

Step 12: Compress the caliper piston

• Place one old brake pad against the piston face.
• Use a C-clamp 6 inch to slowly press the piston fully back into the caliper.
• Watch the brake fluid reservoir level while compressing; remove a little fluid if it gets too full.
• Go slow to protect the master cylinder.

Step 13: Install the new pads

• Install the new inner and outer pads into the bracket by hand.
• Apply brake lubricant to pad backing plate contact points (where the caliper touches), but do not get lube on the pad friction material.

Step 14: Reinstall the caliper

• Remove the temporary lug nuts holding the rotor (if used).
• Set the caliper over the new pads.
• Install the guide pin bolts using a 13mm socket and ratchet 3/8".
• Final tighten with a torque wrench 3/8".
• Torque to 35 Nm (26 ft-lbs)

Step 15: Repeat on the other front wheel

• Repeat Steps 4–14 on the other side.
• Always replace pads and rotors in pairs.

Step 16: Reinstall wheels and torque lug nuts

• Install the wheels and hand-thread all lug nuts.
• Lower the van off the jack stands (rated 3-ton minimum) using the floor jack (rated 3-ton minimum).
• Tighten lug nuts in a star pattern using a torque wrench 1/2".
• Torque to 135 Nm (100 ft-lbs)

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✅ After Repair

• 🦶 With the engine off, slowly pump the brake pedal 10–15 times until it feels firm.
• 🧴 Check brake fluid level and top off with Brake fluid DOT 3 if needed.
• 🔍 Start the engine and confirm the pedal stays firm; check for leaks around the calipers.
• 🛣️ Test drive at low speed first, then do a careful bedding-in: 6–10 medium stops from 35 mph to 5 mph, with cool-down driving between stops.
• 👂 If you hear grinding, stop and recheck caliper mounting and pad placement.

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💰 DIY vs Shop Cost

Shop Cost: $450-$850 (parts + labor)

DIY Cost: $180-$400 (parts only)

You Save: $270-$450 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2-3 hours.

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🎯 Ready to get started?

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