Question about 1996 Dodge Grand Caravan

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96 DODGE CARAVAN FRONT DISC THE CALIPER DOESNT WANT TO SIT PROPERLY ON THE STEERING KNUCKLE, TOO MUCH CLEARANCE AT THE TOP OR BOTTOM WHEN THE PINS ARE TIGHTENED. CAN I GET A PICTURE OF WHAT THE COMPLETED INSTALLATION SHOULD LOOK LIKE?

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  • Jonathan S
    Jonathan S Jul 10, 2010

    The caliper should have a lip that tucks under the steering knuckle.This side of the caliper has to be slid in place first prior to the caliper being tightened.Will try and locate a pic for you

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  • 82 Answers

The steering shaft/Knuckle is a spline shaft very delicately machined, you have perhaps damaged one or more of those machined splines? so it will NOT seat itself properly..Remove the steering arm & use some type of magnification, checking both applications of this unit...
Ur Velcum

Posted on Jul 14, 2010

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1999 Dodge Neon / front callipers, front brakes, rotors in front, and driver side knuckle.


things that have to be checked during a brake replacement process
the caliper pistons have to move back easily when fitting new pads
the caliper body has to move freely on the mounting pins to allow the centralization on the disc rotor
the brake bleeder nipple has to be opened when pushing the pistons back as the displaced fluid build sup pressure in the reservoir
check that the fluid level in the reservoir is not above the full line
check the brake master cylinder is operational and compensating ports are not blocked
basically the problems is that the pads are in contact with the disc and that is generating heat. that heat expands the brake fluid that has to be allowed to flow back to the reservoir
if the expansion of fluid is prevented either by over full reservoir or faulty mastery cylinder preventing the free flow back to the reservoir then the expansion applies the pad more tightly to the disc which in turns creates more heat and more expansion of the fluid
At this point and before you do anything else ,my steps would be to flush the system out using metholated spirits by filling the reservoir and then bleeding each wheel until clear fluid came out
when this is accomplished any black junk in the system is removed
fill the reservoir with new brake fluid and repeat the bleeding process until only brake fluid comes out
Metholated spirits is compatible with brake fluids and is recommended for the purpose
having cleaned out the system and ensured the free movement of the calipers on the mounting pins the pads should be in light contact with the discs and hubs should spin free after brakes are applied and released
In practice pads always touch the disc as there is no method of pulling the ads back and it is the air friction between pad and spinning disc that gives a minute clearance when travelling and if that ability is not allowed then the problems that you have will result

Oct 12, 2015 | Dodge Cars & Trucks

1 Answer

Replace cv joints


Hi Douglas, I'm glad to help. My first suggestion is to get to complete shaft. This way you want have any problems later on. It's not that much more expensive and you'll be glad you did. Below is the procedure for replacing them.



FRONT DRIVESHAFTS

REMOVAL
  1. Raise vehicle on jack stands or centered on a frame contact type hoist. Refer to Hoisting in the Lubrication And Maintenance section of this manual for the required lifting procedure to be used for this vehicle.
  2. Remove the cotter pin and nut lock Hub And Bearing To Stub Axle Retaining Nut from the end of the stub axle.
  3. Remove the wheel and tire assembly from the vehicle.
  4. Remove the wave washer Wave Washer from the end of the stub axle CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires.
  5. With the vehicle's brakes applied to keep hub from turning, loosen and remove the stub axle to hub nut.
  6. Remove the two front disc brake caliper to steering knuckle attaching bolts Front Disc Brake Caliper Attaching Bolts
  7. Remove the disc brake caliper from the steering knuckle. Caliper is removed by first rotating top of caliper away from steering knuckle and then removing bottom of caliper out from under machined abutment on steering knuckle Brake Caliper Mounting To Steering Knuckle
  8. Support disc brake caliper assembly by using a wire hook and suspending it from the strut assembly Correctly Supported Disc Brake Caliper Do not allow the brake caliper assembly to hang by the brake flex hose.
  9. Remove the brake rotor from the hub and bearing assembly Remove/Install Brake Rotor
  10. Remove nut attaching outer tie rod end to steering knuckle Removing Tie Rod End Attaching Nut Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with a wrench.
  11. Remove tie rod end from steering knuckle using Remover, Special Tool MB-991113 Tie Rod End Removal From Steering Knuckle Arm
  12. Remove the steering knuckle to ball joint stud, clamping nut and bolt Control Arm To Steering Knuckle Attachment from the steering knuckle.
  13. Using a pry bar, separate steering knuckle from ball joint stud Separating Ball Joint Stud From Steering Knuckle Note: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly in steering knuckle, end of driveshaft must be supported.
  14. Pull steering knuckle assembly out and away from the outer C/V joint of the driveshaft assembly Steering Knuckle Separation From Driveshaft
  15. Support the outer end of the driveshaft assembly. Insert a pry bar between inner tripod joint and transaxle case Disengaging Inner Tripod Joint From Transaxle Pry against inner tripod joint, until tripod joint retaining snap ring is disengaged from transaxle side gear.
  16. Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod joint from transaxle, by pulling it straight out of transaxle side gear and transaxle oil seal Tripod Joint Removal from Transaxle When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal.
INSTALLATION
  1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant.
  2. Holding driveshaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand Tripod Joint Removal from Transaxle
  3. Grasp inner tripod joint an interconnecting shaft. Forcefully push the tripod joint into side gear of transaxle, until snap ring is engaged with transaxle side gear. Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap ring is fully engaged with side gear, tripod joint will not be removable by hand.
  4. Clean all debris and moisture out of steering knuckle, in the area were outer C/V joint will be installed into steering knuckle.
  5. Ensure that front of outer C/V joint which fits against the face of the hub and bearing is free of debris and moisture before installing outer C/V joint into hub and bearing assembly Outer C/V Joint Inspection
  6. Slide drive shaft back into front hub and bearing assembly. Then install steering knuckle onto the stud of the ball joint assembly Steering Knuckle Separation From Driveshaft
  7. Install a new steering knuckle to ball joint clamping bolt and nut Control Arm To Steering Knuckle Attachment Tighten the clamping bolt and nut to a torque of 135 N·m (100 ft. lbs.)
  8. Install tie rod end into steering knuckle. Start attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a 11/32 socket, Removing Tie Rod End Attaching Nut tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket Torquing Tie Rod End Attaching Nut , tighten the tie rod end attaching nut to a torque of 54 N·m (40 ft. lbs.)
  9. Install braking disc on hub and bearing assembly Remove/Install Brake Rotor
  10. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding bottom of caliper under abutment on steering knuckle, and then rotating top of caliper against top abutment Brake Caliper Mounting To Steering Knuckle
  11. Install disc brake caliper assembly to steering knuckle attaching bolts Front Disc Brake Caliper Attaching Bolts Tighten the disc brake caliper assembly attaching bolts to a torque of 22 N·m (195 in. lbs.)
  12. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install the washer and stub axle to hub/bearing assembly nut on stub axle and securely tighten nut.
  13. Install front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.)
  14. Lower vehicle.
  15. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of 244 N·m (180 ft. lbs.) Torquing Front Stub Axle To Hub Nut
  16. Install the spring wave washer on the end of the stub axle.
  17. Install the hub nut lock, and a new cotter pin Hub And Bearing To Stub Axle Retaining Nut Wrap cotter pin prongs tightly around the hub nut lock as shown in Hub And Bearing To Stub Axle Retaining Nut
  18. Check for correct fluid level in transaxle assembly. Refer to Group 21, Transaxle for the correct fluid level checking procedure for the type of transaxle being checked.
  19. Set front toe on vehicle to required specification.

May 07, 2014 | 2000 Dodge Caravan

1 Answer

How to remove front axle on a 2002 dodge intrepid


raise you vehicle on jackstands. remove front wheel and tire.remove front caliper from steering knuckle assembly, remove rotor from hub by pulling it staright off. remove speed sensor bracket from strut assembly. remove hub and bearing to stub axle retaining nut. dislodge inner CV stub shaft retaining ringon transaxle assembly. insert small pry bar between transaxle case and inner CV joint by prying on it.remove strut assembly to steering knuckle bolts remove top of steering knuckle from strut assembly, then rotate CV assembly out of vehicle. Remove inner shaft from transaxle stub shaft grasp inner CV joint and interconnecting shaft and pull both pieces out at the same time. good luck!

Oct 30, 2010 | Dodge Intrepid Cars & Trucks

1 Answer

I have a chrysler lhs 1994 with a bad front wheel bearing and i need instruction on repair


These are the steps you need to follow for this procedure if you have the proper tools.
  1. Remove front caliper assembly and rotor from the steering knuckle as outlined under "Caliper, Replace" in the "Disc Brake" unit repair section.
  2. Remove hub and bearing to stub axle retaining nut.
  3. Disconnect hub bolts then remove hub and bearing assembly from steering knuckle by sliding it straight off end of stub axle. If metal seal on hub and bearing assembly is seized to steering knuckle and becomes dislodged on hub and bearing assembly during removal, or when removing hub and bearing, the finger disc on hub becomes damaged, hub and bearing assembly must be replaced.
  4. If hub and bearing will not slide out of knuckle, insert a prybar between hub and steering knuckle and gently pry hub and bearing from knuckle.
  5. Tighten stub shaft nut, lower vehicle and with brakes applied, torque stub shaft nut to 70 - 90 ft. lbs.

Aug 27, 2010 | 1994 Chrysler LHS

1 Answer

How do you the rotor off a 1990 honda accord lx


REMOVAL & INSTALLATION Except 1990–95 Accord
  1. If equipped with an air bag, disconnect the negative battery cable and properly disable the Supplemental Restraint System (SRS), as detailed in Section 6 of this manual.
  2. Loosen the lug nuts, then Raise and safely support the vehicle on jackstands.
  3. Remove the wheels.
  4. Remove the two 6mm screws from the brake disc. Fig. 1: Remove the two 6mm screws securing the brake disc 86809029.jpg

  5. Disconnect the caliper from the caliper bracket. Support the caliper out of the way with a length of wire. Do not allow the caliper to hang from the brake hose.
  6. Remove the caliper bracket. Fig. 2: Remove the bolt and guide pin from the caliper bracket, then remove the bracket 86809030.jpg

  7. Remove the brake disc. If the brake disc is difficult to remove, install two 8mm bolts into the threaded holes and tighten them evenly and alternately to prevent cocking the rotor. Fig. 3: Remove the brake disc from the caliper assembly 86809031.jpg

  8. Installation is the reverse of the removal procedure.
  9. If equipped, enable the SRS system and connect the negative battery cable.
1990–95 Accord
  1. If equipped with an air bag, disconnect the negative battery cable and properly disable the Supplemental Restraint System (SRS), as detailed in Section 6 of this manual.
  2. Loosen the lug nuts, then Raise and safely support the vehicle on jackstands.
  3. Remove the wheels.
  4. Remove the steering knuckle from the vehicle. Please refer to Section 8 for procedures.
  5. Remove the 4 bolts retaining the hub unit to the steering knuckle and remove the hub unit. Fig. 4: Remove the 4 bolts retaining the hub unit to the steering knuckle and remove the hub unit/rotor assembly 86809032.gif

  6. Remove the 4 bolts, then separate the hub unit from the brake rotor. Fig. 5: Remove the 4 bolts, then separate the hub unit from the brake rotor 86809033.gif
    To install:
  7. Assemble the disc to the hub unit and tighten the bolts to 40 ft. lbs. (55 Nm).
  8. When installing the hub to the knuckle, use new self-locking bolts and tighten them to 33 ft. lbs. (45 Nm).
  9. Install the steering knuckle.
  10. Lower the vehicle and check for proper brake operation.
  11. If equipped, enable the SRS system and connect the negative battery cable.
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Aug 21, 2010 | 1990 Honda Accord

1 Answer

How do you remove a front axle


Hello
Welcome!
  • The replacement of the CV axle is much easier with the vehicle lifted on a suspension lift. With the minivan in neutral and the steering wheel unlocked, removal of the front tire and then caliper assembly will be required. Remove the entire caliper assembly with pads intact to save a step. Be sure to support the caliper assembly to the coil spring so it does not incur damage to the rubber brake hose.

    The disconnection of the lower ball joint and outer tie rod end will also be required to allow free movement of the steering knuckle. For Caravans that employ speed sensors, remove the wire harness from the knuckle connection as well.

    Remove the cotter pin and castle-headed nut lock from the CV spindle. Next, remove the spring washer and the hub nut. This will require a large socket and breaker bar or a pneumatic gun. To separate the CV axle spindle from the steering knuckle, thread the hub nut back onto the spindle so it's exposing a few threads at the top. Tap on the nut with a large rubber mallet until the splines of the spindle separate from the adjoining knuckle.

    At this point, it's wise to place a drain bucket beneath the transaxle side of the CV joint connection to catch trickling transaxle fluid that will leak out once the connection of the axle to transmission is separated.

    Because the tie rod end and ball joint connections have been separated, you'll be able to manipulate the knuckle from the CV axle spindle. This requires determination and having an assistant would be helpful.

    Once the outer spindle connection of the CV axle is free from the knuckle, you'll need a large pry bar to disengage the inner tri-pot joint out of the transaxle and remove the CV axle from the transmission. This is where some fluid will leak into the drain bucket.
  • To install the new axle, start with the inner connection to the transaxle so that the inner joint circlip seats in the transaxle side gear. An audible click of the circlip should be heard and then test the connection by trying to pull out on the axle by hand. There will be a little free-play in the axle, but if the circlip is seated, you will not be able to disconnect the axle without the aide of the pry bar.

    Next, align the splines of the outer CV axle spindle to the grooves in the steering knuckle. Do not force this connection. Rotate the axle by hand until the splines align properly to the groove. Reconnect the remaining components by reversing the procedure.

    Be sure to torque the hub nut, outer tie rod end nut and ball joint retaining nut to the proper torque specifications of your specific year Caravan. Since the Caravan has been around for quite a while and has employed different engine sizes, there may be a slight variance in the torque specs. A quality repair manual for the specific year and design of your Caravan will display the correct torque specs.

    Last, replace the wheel and then check and adjust the level of the transaxle fluid. Although only a little may have trickled out by the disconnection, the fluid should be topped off to capacity.

  • Let me know if i can help more!

    Jul 17, 2010 | 2006 Dodge Grand Caravan

    1 Answer

    How long does it take to fix front bearings on a 97 dodge caravan? and cost


    About an hour a side...This is the whole job and pictures....

    The hub and wheel bearing unit is serviced as a complete assembly. Replacement of the front drive hub and bearing assembly can be done without having to remove the steering knuckle from the vehicle. However, if the hub/bearing assembly is frozen to the steering knuckle, removal of the steering knuckle is required.
    1. Disconnect the negative battery cable.
    2. Remove the cotter pin from the end of the stub axle. Remove the nut lock and spring washer. With the brakes applied, loosen, but do NOT remove the axle nut and washer with the vehicle still on the ground or damage to the wheel bearing will result.
    3. Raise and safely support the vehicle. Remove the wheel.
    4. Remove the front brake caliper assembly from the steering knuckle assembly and support from the strut assembly using a strong piece of wire.
      1. Remove the front brake rotor from the hub/bearing assembly.
      2. Remove the retaining nut and washer from the halfshaft stub axle.
      3. Remove the ABS wheel speed sensor from the steering knuckle.
      4. Remove the 4 hub and bearing assembly mounting bolts from behind the steering knuckle.
      5. Remove the hub and bearing assembly from the steering knuckle.
    5. To install:
      1. Thoroughly clean the mating surfaces of the steering knuckle and the hub and bearing assembly of any foreign material or nicks so the surfaces are clean and smooth.
      2. Install the new hub and bearing assembly and tighten the mounting bolts in a crisscross pattern to 45 ft. lbs. (65 Nm). Be sure the hub and bearing assembly is seated squarely against the front steering knuckle.
      3. Install the disc brake rotor.
      4. Install the brake caliper assembly onto the steering knuckle.
      5. Install the axle washer and nut. Tighten but do not torque.
      6. Install the ABS wheel speed sensor.
      7. Install the wheel and lug nuts. Torque the lug nuts, in sequence, to 95 ft. lbs. (129 Nm).
      8. Lower the vehicle. Do NOT roll the vehicle until the axle nut has been properly torqued or damage to the front wheel bearings will result.
      9. With the vehicle's brakes applied, torque the axle nut to 180 ft. lbs. (244 Nm). Install the spring washer, nut lock and a new cotter pin. Wrap the cotter pin prongs tightly around the axle nut lock.
      10. Reconnect the negative battery cable. Check the wheel alignment.

    fe8edd6.gif
    The hub/bearing assembly is attached to the steering knuckle with four bolts


    9733319.gif
    Removing a hub/bearing assembly



    1867b08.gif
    If the hub/bearing is "frozen" to the steering knuckle, separate the ball joint and lightly tap on the hub/bearing from behind



    09233ac.gif
    The hub/bearing assembly should free itself from the steering knuckle

    About $60 a hub.

    May 23, 2010 | 1997 Dodge Caravan

    1 Answer

    Change front disc brakes


    Except Srt-4
    1. Before servicing the vehicle, refer to the Precautions section.
    2. Remove the front wheels.
    3. Remove the 2 caliper to steering knuckle guide pin bolts.
    4. Lift the caliper away from the steering knuckle by first rotating the free end of the caliper away from the steering knuckle. Then, slide the opposite end of the caliper out from under the machined end of the steering knuckle.
    5. Support the caliper from the upper control arm to prevent the weight of the caliper from being supported by the brake flex hose that will damage the hose.
    6. Remove the brake pads from the caliper. Remove the outboard brake pad by prying the pad retaining clip over the raised area on the caliper. Then, slide the pad down and off the caliper. Pull the inboard brake pad away from the piston until the retaining clip is free from the cavity in the piston.
    7. If required, the rotor can be removed by pulling it straight off the wheel mounting studs.
    To install:
    1. Clean all parts well. Inspect the caliper for piston seal leaks (brake fluid in and around the boot area and inboard lining) and for any ruptures of the piston dust boot. If the boot is damaged or fluid leak is visible, disassemble the caliper and install a new seal and boot (and piston, if scored).
    2. Inspect the caliper pin bushings. Replace if damaged, dry or brittle.
    3. Completely compress the piston into the caliper using a large C-clamp or other suitable tool.
    4. Lubricate the area on the steering knuckle where the caliper slides with high temperature grease.
    5. Reinstall the rotor if removed.
    6. Reinstall the brake pads into the caliper. Note that the inboard and outboard pads are different. Make sure the inboard brake shoe assembly is positioned squarely against the face of the caliper piston.

      NOTE Be sure to remove the noise suppression gasket paper cover if the pads come so equipped.

    7. Carefully position the caliper and brake shoe assemblies over the rotor by hooking the lower end of the caliper over the steering knuckle. Then, rotate the caliper into position at the top of the steering knuckle. Make sure the caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses.
    8. Reinstall the caliper guide pin bolts and torque to 16 ft. lbs. (22 Nm).
    9. Reinstall the wheels and torque the lug nuts to 100 ft. lbs. (135 Nm).
    10. Pump the brake pedal until the brake pads are seated and a firm pedal is achieved before attempting to move the vehicle.
    11. Road test the vehicle for proper operation.

    83b8db3.gif

    Apr 23, 2010 | 2000 Dodge Neon

    1 Answer

    How do i replace the brakes?


    1. Raise vehicle.
    2. Remove front wheel and tire assemblies from vehicle.
    3. Remove the two caliper guide pin bolts. NOTE: Note the positioning of the two rail shims between the knuckle's machined abutments and the brake shoes.
    4. Remove caliper assembly from steering knuckle. Proceed by first rotating top of caliper away from steering knuckle, then lifting caliper off bottom machined abutment on steering knuckle. Take care not to lose the two rail shims.
    5. Hang the caliper off to the side using wire or bungee cord. Do not allow the caliper to be supported by the flexible brake hose. Damage to the flexible brake hose may result.
    6. Remove outboard brake shoe by prying the shoe retaining clip over raised area on caliper. Then slide the brake shoe off the caliper
      1. Pull inboard brake shoe away from piston until retaining clip is free from cavity in piston.
      2. Repeat steps 3. through 7. on opposite side of vehicle to remove that sides brake shoes.

    Sep 28, 2009 | 1999 Dodge Intrepid

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