Disc Brake Overhaul

• 1). Park the minivan on a level surface and firmly set the parking brake. Slightly loosen the lug nuts then raise the minivan with a jack. Support the vehicle on a jack stand. Completely remove the lug nuts and pull the wheel off.
  
  
• 2). Remove the two caliper guide bolts. Firmly grasp the caliper and slide it up and off the disc. If the caliper is difficult to remove, grab it with both hands and rock it back and forth to force the brake pads apart slightly then remove it from the disc. Hang the caliper out of the way with a wire hook or a bungee cord. Take care not to damage the flexible brake line.
  
  
• 3). Detach the brake pad retaining clips by carefully prying them off with a screwdriver. Do not damage the clips. Remove the brake pads and shims from the caliper.
  
  
• 4). Loosen the cap on the brake fluid reservoir. Retract the caliper piston with a piston retractor. Alternatively, you can use a large C-clamp by placing the spindle swivel of the clamp on the edge of the piston and hooking the frame end of the clamp onto the back of the caliper. Tighten the clamp to retract the piston into the cylinder. Be careful not to pinch or damage the rubber piston seal. Also, make sure that the brake fluid reservoir does not overflow as the piston retracts, causing brake fluid to back up into the reservoir. Tighten the reservoir cap.
  
  
• 5). Remove the disc by pulling it straight off the hub. If the disc is seized, thread two 8 millimeter bolts into the holes in the center part of the disc. Simultaneously, tighten the bolts to jack the disc off the hub.
  
  
• 6). Measure the thickness of the brake pad linings. If any linings are less than 0.0787 of an inch or if the lining wear is uneven, then the pads must be replaced. Measure the thickness of the brake disc at several locations with a brake disc micrometer. If the thickness is less than 1.02 inches at any location or if the disc is warped, cracked, or otherwise irreparably damaged, then the disc must be replaced. Minor damage on the disc surface can be repaired by having the disc machined at a brake shop or auto parts supply store.
  
  
• 7). Clean the parts with brake cleaning fluid. Be sure to catch all used fluid in a catch pan and dispose of the fluid in accordance with local regulations. Lubricate the caliper guide bolts with brake grease. Reassemble the brake by following the steps above in the reverse order. Start the minivan and test the brake operation. Reinstall the wheel and lower the vehicle.
  
  

Drum Brake Overhaul

• 1). Park the vehicle on a level surface and block the front wheels to prevent it from rolling. Leave the parking brake off. Use a lug nut wrench to loosen the lug nuts on both rear wheels. Elevate the rear of the minivan with a jack and set it securely on jack stands. Remove both rear wheels.
  
  
• 2). Remove the two screws that hold the drum to the hub. Pull the drum straight off the hub. If the drum is seized, firmly tap the drum with a hammer or mallet to loosen it. Locate the square parking brake cable tensioner bolt under the minivan on the driver's side and unscrew the nut to release tension on the parking brake cable.
  
  
• 3). Use a pair of pliers to grip the spring end of the adjuster lever spring and unhook it from the adjuster lever. Unhook the other end of the spring from the brake shoe and set the spring aside.
  
  
• 4). Turn the adjuster star wheel to relieve the spring tension on the brake shoes. Pull out the adjuster lever and set it aside. Rotate the adjuster wheel to release tension on the brake shoes. Remove the strut spring by unhooking both ends with the pliers. Remove the lower retracting spring and the upper return spring in the same manner. Set the springs aside.
  
  
• 5). Remove the hold-down pin and spring that hold the primary (front) brake shoe to the backing plate. Use pliers to grip the pin. Depress and rotate the pin until it lines up with the groove in the backing plate then slide the pin and spring straight out. Unhook the anchor spring from both brake shoes. Pull the primary shoe off the backing plate and slide the adjuster wheel assembly and the adjuster lever assembly off of the secondary (rear) brake shoe. Use pliers to pull the retaining clip off of the retaining pin then pull the parking pivot lever off the back of the shoe.
  
  
• 6). Detach the hold-down pin and spring that hold the secondary brake shoe to the backing plate. Use pliers to grip the pin. Depress and rotate the pin until it lines up with the groove in the backing plate then slide the pin and spring straight out. Carefully pull the secondary shoe away from the backing plate. Remove the parking brake cable from the secondary shoe by sliding the cable end out from in between the retaining tines.
  
  
• 7). Measure the inside diameter of the brake drum with a brake drum micrometer. The diameter should be the same, regardless of which direction it is measured, indicating that the drum is round. The maximum allowable drum diameter is 10.07 inches. The interior surface of the drum should not have any deep grooves, glazed spots or cracks. If the drum shows signs of irreparable damage or if the diameter exceeds the allowable maximum, then the drum must be replaced. Minor damage to the inside of the drum can be repaired by having the drum machined at a brake shop or auto parts supply store. Measure the lining thickness on the brake shoes. The minimum allowable thickness is 0.04 of an inch. If the lining thickness is less than the allowable minimum, then the shoes must be replaced.
  
  
• 8). Clean all parts with brake cleaning fluid. Use rags and a wire brush to remove stubborn dirt and deposits. Be sure to catch all used fluid in a catch pan and dispose of the fluid in accordance with local regulations. Unthread the two pieces of the adjuster wheel and clean the two halves with brake cleaning fluid. Lubricate the adjuster wheel threads with brake grease before reassembling the two parts. Also apply brake grease to the contact points where the brake shoes touch the backing plate (eight points).
  
  
• 9). Reassemble the brake by following the above steps in the reverse order. Refer to the wheel on the opposite side as a guide. Pump the brakes several times to set the self-adjusting mechanism then test the brakes. Repeat the procedure on the opposite wheel. Replace the wheels then lower the vehicle.