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Caravan/Voyager Brake Issues

79 messages,  Last post on May 18, 2009 at 8:30 AM

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What is this discussion about? Dodge Grand Caravan, Chrysler Voyager, Plymouth Voyager, Brakes, Van

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#1 of 79 97 dodge grand caravan brake caliber problem by cotero1000 Oct 19, 2006 (9:15 am)
I have a problem and not sure how to fix it. I am trying to change my front disc pads on my fan and my top bolt on the caliber is stuck. I can not break it loose. I have tried wd-40 and motor oil and left both sit on for a couple of hours and tried again still nothing. Does anyone have any other suggestions on how to break it loose? I would greatly appreciate any help.   Thank you   cotero1000 Replies to this message: mfahey1 (Nov 08, 2006 4:23 pm)
#2 of 79 Re: 97 dodge grand caravan brake caliber problem [cotero1000] by mfahey1 Nov 08, 2006 (4:23 pm)
Replying to: cotero1000 (Oct 19, 2006 9:15 am) WD40 really isn't a rust penetrant. Try PB Blaster or something similar. Also, as long as there isn't a rubber sleeve over the bolt, try heating it with a propane torch and then spraying it with the rust penetrant. Let it cool and go through the whole cycle again. You can also try hitting your rachet with a hammer to provide a shock that might just begin to break it loose.
#3 of 79 Bendix 10 ABS; 1992 T&C by vanpo Nov 14, 2006 (9:49 am)
I have '92 T&C, in very good condition despite showing 208,000 miles. The ABS has failed shutting down the power brakes. I am afraid Chrysler would charge more to repair it than the van is worth. I plan to remove the ABS components and replace them with non-ABS parts from a local salvage yard. Has anyone done this procedure? If so, please provide some details. TYVM, Vanpo
#4 of 79 Check with Chrysler. by vcheng Nov 14, 2006 (11:13 am)
I think, but am not sure, that the Bendix 10 ABS pump and other parts are covered by a lifetime warranty, no matter how old the vehicle. Of course, the fine print may mean that other parts required to complete the work may cost you, but the pump itself would be covered by the warranty. Replies to this message: vanpo (Nov 15, 2006 8:14 am)
#5 of 79 Re: Check with Chrysler. [vcheng] by vanpo Nov 15, 2006 (8:14 am)
Replying to: vcheng (Nov 14, 2006 11:13 am) Thanks for your information, I will check it out. However, I do not wish to spend over $200 on a fix and regardless, I doubt if Chrysler will settle for that. Therefore I still want more information on converting the ABS system to non-ABS. The salvage yards are full of non-ABS wrecks ('91-'93)and I can get the main components for less than $100. I just need some guidance on how to install these parts so that the hookup is proper. I would like to get a brakeline diagram showing the line routing and hookup to the "combination valve". Thank you for any advise/information you can supply. Vanpo.
#6 of 79 A conversion with ... by vcheng Nov 15, 2006 (9:26 am)
... salvage parts is certainly feasible. Most of the components should bolt right in. Although a good source for the brakeline diagram would be the factory service manual, you may have to get lucky to get one off eBay. However, proper routing is not a big issue. You may have to get a tubing bender and a flare tool in addition to generic brake line lengths, but that is not expensive.   Remember, the brakes are critical. Please put in the time and effort to do it right.
#7 of 79 T&C non-ABS conversion, Vcheng, TYVM by vanpo Nov 16, 2006 (6:56 pm)
I have picked up a master cylinder (with a vacuum booster) and the associated switch block. I already have the tools. At 75 years age, I am not as ambitous to use them as I once was. Hopefully, I can finish the job for $150 total(parts). My experience with complex items of this nature is that they don't get better as the car ages. For that reason I want to simplify the system. I did locate a diagragm in an online subscription of a service manual for the '92 T&C (ALLDATA/AutoZone). Vanpo
#8 of 79 Good Luck man! by vcheng Nov 17, 2006 (4:23 am)
#9 of 79 Seeking DIY instructions for 2005 Grand Caravan brake job by djuggler Nov 21, 2006 (11:54 am)
The Haynes manual for the 2005 Grand Caravan does not release until February 2007. Chilton doesn't have one either. The dealship suggests I order a shop manual for $50 (which would be nice but I need to finish the brake job before the manual would arrive).   Obviously brakes are not rocket science. However, caliper torque settings would be nice. Does anyone have a link to an online reference for changing brake shoes and discs for a 2005 Dodge Caravan? Or even just the torque settings and words of advice?
#10 of 79 Replace rear brake lines - 97 Grand Voyager by diy Dec 22, 2006 (12:20 pm)
The rear brake lines from the ABS to the back need to be replaced because they have rusted through. I discussed this with the two dealers. One says the brake line are special order. The other says the line is roll steel and must be fabricated. Estimates are $400 and $600 respectively.   At first it appears to be an easy job of unbolting the lines at the ABS unit to the back axle. But after a second look,the ABS support bracket is in the way.   What is involved in removing this bracket?

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