Tools You'll Need:
* Jack and jack stands: To safely lift the vehicle.
* Wheel chocks: To prevent the vehicle from rolling.
* Lug wrench: To remove the wheel.
* Socket wrench set (metric): You'll need various sizes.
* C-clamp or rotor removal tool: To compress the caliper piston.
* Wrench or socket to remove caliper mounting bolts: This size varies depending on your Caravan's model.
* Penetrating oil (PB Blaster or similar): To help loosen any rusty or seized bolts.
* Clean rags or shop towels: To clean up brake dust and fluid.
* Safety Glasses: Protect your eyes from flying debris.
* Gloves: Protect your hands from grease and grime.
Steps:
1. Safety First: Park on a level surface, engage the parking brake firmly, and chock the rear wheels. Use jack stands to lift the front end of the vehicle securely after using the jack to raise it.
2. Remove the Wheel: Remove the lug nuts using the lug wrench. Carefully remove the wheel and set it aside.
3. Expose the Caliper: You'll see the brake caliper clamping onto the rotor.
4. Compress the Caliper Piston: Before removing the caliper, you MUST compress the piston to create space for the rotor to be removed. Use a C-clamp or a specialized caliper piston compression tool. Be careful not to damage the piston or boot. If you're using a C-clamp, use a block of wood to distribute pressure evenly on the caliper piston. Slowly and steadily compress the piston; if you push it too fast, you might force brake fluid out of the reservoir, leading to a mess and possibly air in the brake lines.
5. Remove the Caliper: Once the piston is compressed, remove the bolts holding the caliper to the caliper bracket. Carefully lift the caliper away from the rotor and support it with a bungee cord or wire to keep it out of the way. Do not let the caliper hang by the brake line.
6. Remove the Rotor: Now, the rotor should be free to slide off the hub. Sometimes, they can be a little stuck due to rust. If it's difficult, gently tap it from the back with a rubber mallet or a block of wood and a hammer to loosen it. Avoid damaging the wheel studs.
7. Clean the Hub: Thoroughly clean the wheel hub mounting surface of any rust, brake dust, or debris.
8. Install the New Rotor (Reverse Order): Install the new rotor, making sure it sits flush against the wheel hub. Then reassemble everything in the reverse order of removal.
9. Bleed the Brakes (Important): After reinstalling the caliper and refilling the master cylinder reservoir (if necessary), bleed the brakes to remove any air that might have entered the system during the piston compression process. This is crucial for proper brake function.
Important Considerations:
* Brake Fluid: If you're dealing with brake fluid, be cautious as it can damage paint and is harmful to the skin. Use gloves and clean up any spills immediately.
* Torque Specifications: Always refer to your vehicle's repair manual for the correct torque specifications for the lug nuts and caliper bolts. Over-tightening can damage components, and under-tightening can lead to loosening and failure.
* Professional Help: If you are uncomfortable with any of these steps, it is always best to seek professional help from a qualified mechanic. Brake work is crucial for your safety.
This is a general guide. Consult your vehicle's repair manual for the specifics of your 2002 Dodge Caravan. Improperly performed brake work can be dangerous. If you're unsure about any step, have a qualified mechanic do the work.
