The 1997 Plymouth Grand Voyager uses front disc brake pads and can sometimes feature rear disc brake pads. While rear drum brakes are more common on this vehicle, replacing the front and/or rear brake pads employs the same procedure. Like its cousin, the Dodge Grand Caravan, the brake pads on these minivans are clipped to the caliper housing. The outer pad clips to the outer housing with spring clips, while the inner pad uses a spring clip the sits inside the hollow caliper piston. These clips are riveted to the backing plates of the pads.
Instructions
- 1
Wedge a tire blocking device behind one of the rear wheels if replacing front brake pads or in front of one of the front wheels if replacing rear brake pads.
2Apply the parking brake if replacing the front brake pads, and release the primary hood release latch inside the Grand Voyager.
3Release the secondary hood release latch, open the hood and support it on the hood prop rod. Remove the master cylinder cap and use the clean suction syringe to remove half of the brake fluid. Dispose of the fluid, and replace the cap.
4Crack the wheel nuts loose on the two tires of the axle on which you're replacing the pads using the tire lug wrench to turn the nuts one-half turn counter-clockwise.
5Lift with a jack each front or rear quarter panel high enough to support the minivan safely and securely onto jack stands and then remove the wheel nuts and tires.
6Remove the inner caliper mounting screws with the ratchet and a compatible socket. Pry the caliper off of the rotor using a pry tool, and then use the pliable, sturdy wire to tie the caliper to the front or rear chassis. This will alleviate damage from occurring to the rubber brake hose line attached to the caliper.
7Unseat the clips of the outside pad from the caliper housing using the pry tool to release the clips off of the outer caliper housing.
8Insert the caliper piston compression clamp to the inner outside housing of the caliper and the compression screw placed against the face of the inside pad. Tighten the clamp in a clockwise motion to compress the piston fully into the caliper piston bore.
9Remove the inside brake pad from the caliper piston bore by pulling upward on it and releasing the retaining clip from the steel plate of the pad.
10Insert the inside brake pad and retaining clip into the caliper piston first, and then pry the outside brake pad clips onto the outer caliper housing.
11Replace the caliper and pads over the brake rotor, and replace the caliper mounting bolts. Hand-thread the bolts to avoid cross-threading them. Tighten them with the ratchet and a compatible socket.
12Replace the wheels and wheel nuts. Tighten the wheel nuts employing a star pattern with the tire lug wrench until the nuts are seated against the hub tightly, and then lower the minivan to the ground. Use the 100-foot lb. torque wrench with a 3/4-inch or 19-mm socket to re-tighten the lug nuts, again employing the star pattern.
13Pump the brake pedal until it feels firm, and then check the brake fluid level in the master cylinder. If necessary, fill the master cylinder with brake fluid, release the parking brake, if applicable, and then remove the tire blocking device before test driving the Grand Voyager.
