Tools You'll Likely Need:
* Jack and jack stands (essential for safety!)
* Lug wrench
* Wheel chocks
* Socket wrench set (metric)
* Combination wrench set (metric)
* Brake caliper piston compressor tool (essential)
* C-clamp (can sometimes substitute for a caliper compressor)
* Torque wrench
* Wire brush
* Brake cleaner
* New brake pads
* New rotors (likely needed, but assess their condition first)
* Penetrating oil (like PB Blaster)
* Gloves
* Safety glasses
General Steps:
1. Safety First: Park on a level surface, engage the parking brake, and chock the front wheels. Use jack stands to safely lift the rear of the vehicle. Never work under a vehicle supported only by a jack.
2. Remove the Wheel: Remove the lug nuts and carefully remove the wheel.
3. Inspect the Brakes: Assess the condition of the brake pads, rotors, and calipers. Measure pad thickness to determine if replacement is necessary. Rotors should be inspected for scoring, grooves, or excessive wear. If in doubt, replace them.
4. Remove the Caliper: The specific method for caliper removal varies slightly depending on the brake system design. You may need to remove caliper mounting bolts. Often, you can carefully support the caliper with wire or a bungee cord to avoid letting the brake line hang.
5. Compress the Caliper Piston: This is crucial! Use the caliper piston compressor tool to slowly and evenly compress the caliper piston. This creates space for the new, thicker brake pads. If you don't compress the piston, you won't be able to install the new pads.
6. Remove the Brake Pads: Carefully remove the old brake pads. Clean the caliper mounting bracket with a wire brush.
7. Install New Brake Pads: Install the new brake pads, ensuring they slide smoothly into their slots.
8. Install the Caliper: Reinstall the caliper, ensuring it's properly seated and the mounting bolts are tightened to the manufacturer's specified torque.
9. Install the Rotor (if needed): If replacing the rotors, clean the mating surfaces thoroughly before installing the new rotors.
10. Reinstall the Wheel: Reinstall the wheel and tighten the lug nuts to the manufacturer's specified torque.
11. Lower the Vehicle: Carefully lower the vehicle to the ground.
12. Pump the Brakes: Several times firmly pump the brake pedal to ensure the system is working correctly. If the pedal goes almost to the floor, you may have air in the lines (bleeding might be necessary).
13. Test Drive: Test drive the vehicle carefully, checking for proper braking performance. If anything seems amiss, STOP and re-check your work.
Important Considerations:
* Brake fluid: While not directly part of pad replacement, you should check your brake fluid level. If it's low, you might have a leak that needs addressing.
* Bleeding the brakes: If you have to remove the brake line for any reason, or experience a very soft brake pedal after reassembly, you may need to bleed the brakes to remove trapped air.
* Parking brake: Some models have a separate parking brake mechanism that might require adjustment. Consult your repair manual.
* Caliper slide pins: Inspect the caliper slide pins for movement and lubricate with high-temperature brake grease if needed.
Again, this is a simplified overview. Refer to a repair manual specific to your 2004 Chrysler Town & Country for detailed, step-by-step instructions and torque specifications. If you're not comfortable performing this task, it's always best to take your vehicle to a qualified mechanic. Improper brake repair can be extremely dangerous.
