Hey guys. Getting ready to replace the rear brakes on my 2009 Grand Caravan SXT w/ the 3.8l engine. I've only tackled this kind of jobs a couple times before, and it's been many years.

The van has discs in the back as well.

A Few questions.

1. Can anyone direct me to a diagram of the rear assembly and brake components?
2. Will I need any really funky or odd tools, outside of the normal tools?
3. Do you have any great online source for parts you would recommend?


Thanks VERY much in advance,
Chris

 

REMOVAL







NOTE: Before proceeding, (Refer to 05 - Brakes - Warning) (Refer to 05 - Brakes - Caution) . 1.Raise and support vehicle.
NOTE: Perform Step #2 through Step #8 on each side of vehicle to complete pad set removal. 2.Remove wheel mounting nuts (3), then tire and wheel assembly (1).



CAUTION: 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.
3.Remove two caliper guide pin bolts (1).4.Remove the disc brake caliper (2) from the disc brake adapter bracket and hang it out of the way using wire or a bungee cord. Use care not to overextend the brake hose or parking brake cable when doing this.


5.Prior to pad removal, inspect for freedom of pads to slide on caliper adapter.6.Remove the brake pads (2, 5) from the caliper adapter bracket (3).


7.If pads show signs of very uneven wear, and/or pads did not slide easily on adapter, replace adapter bracket. Remove two mounting bolts (2) and remove bracket.8.If pads did not show signs of very uneven wear, remove and discard old pad shims, and clean abutments (area behind shims) of any debris or corrosion.

 

Thanks!!!! ;-)

 

INSTALLATION


Special Tools: Click to display a list of tools used in this procedure


NOTE: Perform Step #1 through Step #7 on each side of vehicle to complete pad set installation, then proceed to Step #8 .
CAUTION: Anytime the brake rotor or brake pads are being replaced, the rear caliper piston must be seated (bottomed) to compensate for the new brake rotor or lining. Because the parking brake self-adjuster mechanism is attached to the piston, a special seating method is required. The only acceptable method is by rotating the piston back into the bore using Retractor, Special Tool 8807 , as described below. Any other seating method will damage the self-adjuster mechanism.

1.If necessary, seat (bottom) the caliper piston in the bore as follows: a.Assemble a 3/8 in. drive ratchet handle and an extension (3).b.Insert the extension through Special Tool 8807-1 (2).c.Place Special Tool 8807-2 (1) on the end of the extension.d.Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5).e.Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f.Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction.

2.If caliper adapter was replaced, install caliper adapter bolts (2) and tighten to 100 N-m (74 ft-lbs).



NOTE: There are two different abutment shims. If installed in wrong orientation, pads will not fit properly.
NOTE: If the brake pads have a protective paper on the rear face of the brake pad plate, it must be removed before pad installation. 3.Assure adapter abutments are free from debris or corrosion. Apply an even layer of Mopar© Brake Lubricant or equivalent to entire area of four abutments PRIOR to shim installation. Install four new pad shims (4). 4.Place the brake pads (2, 5) in the abutment shims (4) clipped into the disc brake caliper adapter bracket (3) as shown.



CAUTION: Use care when installing the caliper (2) onto the adapter bracket to avoid damaging the guide pin boots.
CAUTION: 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.
5.Install the disc brake caliper (2) over the brake pads on the brake caliper adapter bracket.6.Align the caliper guide pin bolt holes with the adapter bracket. Install the upper and lower caliper guide pin bolts (1). Tighten the guide pin bolts to 35 N·m (26 ft. lbs.).


7.Install tire and wheel assembly (1) (Refer to 22 - Tires and Wheels - Installation) . Install and tighten wheel mounting nuts (3) to 135 N·m (100 ft. lbs.).8.Lower vehicle.9.Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.10.Check and adjust brake fluid level as necessary.11.Road test vehicle and make several stops to wear off any foreign material on brakes and to seat brake pads.

 

And spray some lube between the piston and the boot before you screw it in.

 

Outstanding, thank you, Sir! ;-)