🔧 Grand Caravan - Rear Brake Pads & Rotor Replacement

Replacing the rear brake pads and rotors restores safe stopping power and prevents grinding, pulsation, and uneven braking. On your Grand Caravan, the rear calipers include the parking brake mechanism, so the piston must be turned while being pushed back.

Difficulty Level: Intermediate | Estimated Time: 2.0-3.5 hours

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⚠️ Safety & Precautions

• ⚠️ Work on level ground and chock the front wheels before lifting the rear.
• ⚠️ Release the parking brake before starting, or the rear calipers/rotors won’t come off correctly.
• ⚠️ Support the van with jack stands; never rely on a floor jack alone.
• ⚠️ Do not let the caliper hang by the brake hose; support it with a hanger.
• ⚠️ Avoid breathing brake dust; use brake cleaner, not compressed air.
• ⚠️ Brake fluid can damage paint; wipe spills immediately.
• 🔋 Battery disconnect is not required for this repair.

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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
• 21mm socket
• 3/8" drive ratchet
• 1/2" drive breaker bar
• Torque wrench (20-200 ft-lbs range)
• 13mm socket
• 18mm socket
• Caliper piston wind-back tool (specialty)
• Wire brush
• Bungee cord
• Flathead screwdriver
• Rubber mallet
• Brake cleaner spray
• Disposable gloves
• Safety glasses

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Rear brake pad set - Qty: 1
• Rear brake rotors - Qty: 2
• Brake caliper slide pin grease (silicone brake grease) - Qty: 1
• Brake hardware kit (rear pad clips/shims) - Qty: 1
• Brake fluid (DOT 3) - Qty: 1 quart

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📋 Before You Begin

• Park on level ground, put the shifter in Park, and release the parking brake.
• Place wheel chocks in front of both front tires.
• Loosen rear wheel lug nuts 1/2 turn using a 21mm socket and breaker bar before lifting.
• Open the hood and remove the brake fluid reservoir cap (leave it sitting loosely). This helps fluid move back when compressing caliper pistons.
• Tip: Put a rag under the reservoir to catch spills.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Lift and support the rear

• Lift the rear using a floor jack (rated 3-ton minimum) at the rear jacking point.
• Set the van down onto jack stands (rated 3-ton minimum) at solid support points.
• Remove the rear wheels using a 21mm socket.

Step 2: Locate the rear caliper and remove it

• Turn the steering wheel slightly if needed for more room (front wheels only), then move to the rear brakes.
• Remove the two rear caliper guide/slide pin bolts using a 13mm socket and 3/8" ratchet.
• Lift the caliper off the bracket and support it with a bungee cord (do not stress the hose).

Step 3: Remove old pads and inspect slide pins

• Pull the brake pads out of the bracket by hand. Use a flathead screwdriver gently if they’re stuck.
• Pull the slide pins out of the bracket (they are the smooth pins the caliper slides on).
• Wipe old grease off and check that each pin moves smoothly.
• Apply a thin coat of brake caliper slide pin grease (silicone brake grease) and reinstall the pins.

Step 4: Remove the caliper bracket

• Remove the two caliper bracket bolts using an 18mm socket and breaker bar.
• Set the bracket aside.
• During reassembly: Torque caliper bracket bolts to 95 Nm (70 ft-lbs).

Step 5: Remove the rotor

• Pull the rotor straight off the hub.
• If it’s stuck from rust, spray the hub/rotor center with brake cleaner spray, then tap the rotor hat with a rubber mallet to break it free.
• Clean rust off the hub face using a wire brush. A clean hub helps prevent brake pulsation.

Step 6: Install the new rotor

• Spray both sides of the new rotor with brake cleaner spray to remove protective oil.
• Install the rotor onto the hub.
• Tip: Put one lug nut on finger-tight to hold the rotor flat.

Step 7: Install new pad hardware and pads

• Install the new pad clips/shims from the brake hardware kit (rear pad clips/shims) into the bracket.
• Clean the bracket “pad lands” (where clips sit) with a wire brush so the pads slide freely.
• Install the new pads into the bracket by hand.

Step 8: Wind back the rear caliper piston (parking brake style)

• Use a caliper piston wind-back tool (specialty) to push and turn the piston clockwise at the same time until it seats fully.
• A wind-back tool is a tool that rotates the piston while applying pressure, which is required on rear calipers that incorporate the parking brake mechanism.
• Watch the brake fluid reservoir while doing this. If it rises near the top, remove some fluid (do not overflow).

Step 9: Reinstall the caliper

• Place the caliper over the new pads.
• Install the caliper guide/slide pin bolts using a 13mm socket.
• Torque caliper guide/slide pin bolts to 35 Nm (26 ft-lbs).

Step 10: Reinstall wheels and torque lug nuts

• Reinstall the wheels and snug the lug nuts using a 21mm socket.
• Lower the van off the jack stands using the floor jack.
• Torque lug nuts to 135 Nm (100 ft-lbs) in a star pattern using a torque wrench.

Step 11: Pump the brake pedal and set fluid level

• With the engine OFF, pump the brake pedal slowly 10-15 times until it feels firm.
• Check the brake fluid level and top off with brake fluid (DOT 3) if needed.
• Reinstall the reservoir cap.

Step 12: Check parking brake operation

• Apply and release the parking brake a few times to ensure it works smoothly.
• If a wheel drags heavily with the parking brake released, recheck caliper piston wind-back and pad fitment.

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✅ After Repair

• Start the engine and confirm the brake pedal remains firm.
• Road test at low speed first. Listen for grinding or clunks.
• Perform a gentle bed-in: make 6-8 medium stops from 30 mph down to 5 mph, with 30 seconds between stops.
• Recheck brake fluid level after the test drive.
• Tip: Avoid hard stops for the first 200 miles.

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💰 DIY vs Shop Cost

Shop Cost: $450-$900 (parts + labor)

DIY Cost: $140-$320 (parts only)

You Save: $310-$580 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?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.