AboutRoland Finston Expertise I take questions about domestic Chrysler-product front wheel drive cars and minivans for the years 1982-2000 based upon my experience and shop manuals. I don't have detailed information (e.g. manuals) nor expertise for Jeeps, trucks, SUV's, import vehicles, or for years more recent than 2000 (except Sebring/Stratus I have '03).
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Experience I have been a do-it-yourself auto hobbyist for 5 decades, and most recently have been concentrating on the various Chrysler Corporation domestic front wheel drive cars and vans. I have shop manuals and wiring diagrams for many models for the years '83-'00, as well as rear wheel drive cars for the early 80's. I enjoy analyzing problems that other Chrysler enthusiasts are having and sharing my information.
Organizations belong to Group co-moderator of the Yahoo autos group The Chrysler LeBaron Club
Expert: Roland Finston Date: 7/21/2008 Subject: '02 Dodge Grand Caravan Rotor Replacement
Question QUESTION: Hello Roland,
This is just a quick question... what's the best way to lossen a stubborn bolt? I'm changing the rotors on my '02 Dodge Grand Caravan, and I'm having the hardest time removing the large bolts that seem to have seized themselves on the housing to the brake caliper.
I've tried "Liqid Wrench", but to no avail. I'm also coming close to stripping the bolt as I have tried to apply force while using my lug wrench.
Am I even removing the right part? The rotor is being blocked by this "housing".
Once again, thanks so much for your help.
dj
ANSWER: Hi DJ,
Try tapping on them to help drive the liquid wrench into the threads. Also, try driving the van and do sufficient braking to heat up all the brake parts including the bolts in question as that can help loosen things too, in the absence of a torch which is another way to loosen them up. Also, though counter-intuitive, you might try rocking the torque back and forth, thighter and looser, as this will also help break the bind-up in many circumstances. Finally, I would encourage you to use a well-fitting socket and breaker bar so that you don't round off the flats on the bolt head before it is loose. If you are speaking of the two guide pins that secure the caliper to the mounting, located on the inboard side, those are set to be torqued to 40 foot-pounds, when assembled. But they may be rusted which is why you can't free them. I would get new guide pins so that once you have it apart you will have good "flats" once again. Be careful when installing to be sure the pins are squarely aligned to the holes in the mounting so as not to cross-strip the threads when you begin to tighten them.
Roland
Hi DJ,
Stop! You shouldn't have to remove the mounting. Just the caliper. Once the guide bolts are out, use a screwdriver with the tip placed on the edge of the rotor, and the shaft pressing against the upper end's edge of the caliper assembly to lever that upper end outward and then once you have done that, you can lift the caliper so that the lower edge of the caliper comes off the machined lower edge of the mount and that gives you full access to the rotor. You will want to support the caliper by tieing it up to the upper strut/spring so that the brake hose isn't stressed. And you will want to lever the caliper piston back into its cylinder in the caliper enough so as to gain the extra opening width to compensate for the fact that the new disc is wider than the old. To do that use a piece of wood that is about as thick as the opening but wider in the other direction so that you can rotate the wood with the help of an open end wrench and thus push the piston surface back into the cylinder.
Roland
---------- FOLLOW-UP ----------
QUESTION: Hello Roland,
I must not be looking at the right thing. I successfully removed the caliper and pushed the piston back, but the rotor is still being blocked by the mount. I can't just slide it off like I can on my other vehicles.
Thanks,
dj
Answer Hi DJ,
I don't have a manual newer than '99 so the design must have changed by '02. Sorry I can't give you any personal experience. I just replaced the front rotor on my '89 Lebaron that has the Kelsey Hayes single pin caliper and of course the rotor came right off after the caliper was removed. I would be interested to know how things work out. It is a front rotor you are working on, correct?
Roland
