I have a 2001 Grand Caravan. I bought new pads and rotors. The rotors are scored and pitted. I can't get them off. Is it necessary to remove the 34mm nut behind the cotter pin? Also is there an approved method for getting everything done? Perhaps a step by step for brake virgins?

 

dont touch the big nut, just hit on the rotor with a hammer near the wheel studs but be careful not to hit the studs.

 

REMOVAL - FRONT BRAKE ROTOR

1. Raise vehicle on jackstands or centered on a frame contact type hoist. See Hoisting in Lubrication and Maintenance.
2. Remove the front wheel and tire assembly.
3. Remove the two mounting bolts securing the disc brake caliper adapter with brake caliper to the steering knuckle (Front Brake Mounting).
4. Remove the disc brake caliper and adapter as an assembly from the steering knuckle (Front Brake Mounting). Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this.
5. Remove any retainer clips from the wheel mounting studs.
6. Remove brake rotor from hub by pulling it straight off wheel mounting studs (Front Brake Mounting).

If the rotor won't come off, hit the pad surface of the rotor with a hammer until it pops off. (Assuming you are replacing them)


REMOVAL - FRONT DISC BRAKE SHOES (DISC/DISC BRAKES)

1. Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE).
2. Remove both front wheel and tire assemblies.
3. Begin on one side of the vehicle.
4. Remove the anti-rattle clip from the outboard side of the caliper and adapter.
5. Remove the two caliper guide pin bolts.
6. Remove caliper from caliper adapter and brake rotor. CAUTION: Supporting weight of caliper by the flexible brake fluid hose can damage the hose.
7. Using wire or cord, hang the caliper from the front strut assembly (Stored Front Disc Brake Caliper). Support the caliper firmly to prevent weight of caliper from being supported by the brake fluid hose.
8. Remove the outboard brake shoe from the caliper adapter.
9. Pull the inboard brake shoe away from the caliper piston until the retaining clip on shoe is free from the cavity in the caliper piston (Removing Inboard Shoe).
10. Repeat the above procedure on other side of the vehicle.

INSTALLATION - FRONT DISC BRAKE SHOES (DISC/DISC BRAKES)

NOTE: There may be more than 1 lining material released. Make sure proper linings are being installed.

1. Begin on one side of the vehicle or the other.
2. Completely retract the caliper piston back into its bore in the brake caliper (This is required for caliper installation on the brake rotor with new brake shoes installed).
3. If applied, remove the protective paper from the noise suppression gasket on the rear of both the inner and outer brake shoe assemblies.
4. Install the new inboard brake shoe into the caliper piston by firmly pressing its retaining clip into the piston bore. Be sure the inboard brake shoe is positioned squarely against the face of the caliper piston.
5. Lubricate both adapter abutments where the shoes slide with a small amount of Mopar® Dielectric grease, or equivalent.
6. Slide the new outboard brake shoe into the caliper adapter with the lining up against the outside of the brake rotor. CAUTION: Use care when installing the caliper assembly onto the caliper adapter, so the caliper guide pin bushings do not get damaged by the adapter bosses.
7. Carefully position the brake caliper over the brake rotor and adapter.
8. Install the caliper guide pin bolts and tighten to a torque of 35 N·m (26 ft. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts.</B>
9. Install the caps over the caliper guide pin bolts.
10. Install the new caliper hold down spring (anti-rattle clip) on the outboard side of the caliper. Start the spring into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter.
11. Repeat the above procedure on other side of the vehicle.
12. Install the wheel and tire assemblies. Tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.).
13. Lower vehicle.
14. Pump the brake pedal several times. This will set the shoes to the brake rotor.
15. Check and adjust brake fluid level as necessary.
16. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes.

 

Thank you very much. IF you see new posts after tomorrow, you will know I lived through the test drive! Thanks again.