Calipers control the brake pads.
Your 1994 Plymouth Voyager has disc brakes in the front and drum brakes in the rear. The front disc brake pads will normally require replacement every 25,000 to 30,000 miles, while the rear brake shoes will need to be changed at approximately 40,000 to 50,000 miles. Disc brake pad and drum brake shoe replacement is a job that you can accomplish in your garage or front yard in about two to two and a half hours.
Instructions
Front Disc Brakes
1. Slide the new pads onto the adapter.6. Slide the caliper over the adapter and pads. Insert the slider pins into the corresponding holes and rotate them clockwise until finger tight. Don’t remove it completely.
2. Roll the jack under the front cross-member and lift the front wheels off the ground. Place the jack stands on either side of the jack. Carefully lower the vehicle onto the stands, making sure the front wheels are off the ground. Remove the lug nuts and wheels.
3. Coat the backs of the brake pads with the supplied pad adhesive. Remove the two slider pins from one of the calipers by turning the pin counterclockwise with the ratchet and the correct socket. These are usually either ½- or 9/16-inch. Set these pins aside.
4. Pull the caliper away from the rotor with a rocking motion. Hold one of the brake pads on the caliper piston and clamp it in place with the C-clamp. Turn the screw on the clamp until the piston is completely compressed. Remove the clamp.
5. Verify the location of the brake pad clips and move them to the corresponding places on the new pads. Loosen the lug nuts on the two front wheels by turning them counterclockwise with the lug wrench. Place the wheel chocks in front of and behind one rear wheel. Loosen the cap on the brake fluid reservoir.
Tighten the pins to between 40 and 50 foot-pounds.
Rear Brake Shoes
7. Place wheel chocks in front of and behind one front wheel. Loosen the rear wheel lug nuts by turning them counterclockwise with the lug wrench.
8. Slide the jack under one side of the van at the rear and lift until the wheel is completely clear of the ground. Tighten the brake fluid reservoir cap.
9. Remove the dust cap from the hub by pulling with the large slip-joint pliers.
10. Remove the cotter pin from the castellated nut cover and set it aside in the dust cap. Pull the castellated nut cover off and set it into the dust cap. Remove the lock nut by turning it counterclockwise with the large slip-joint pliers and set it into the dust cap. Tap the edge of the brake drum to remove the bearing and place that into the dust cap. Pull the brake drum off and set it aside.
11.24. Slide under the rear of the van and pull the rubber plug from the lower portion of the backing plate. Insert the adjusting tool into the newly exposed opening and spin the wheel by hand. Push down on the handle to rotate the adjuster wheel until you hear the shoes dragging against the brake drum.
Pull the brake adjuster cable off and set it aside. Pull the adjuster cable slider/anchor plate off and set it aside.
13. Squeeze the retaining pin cap with the small pliers and push in and turn one quarter-turn either way to remove. Repeat this process on the other pin. Pull the pins and retaining springs and set them aside.
14. Pull the rearward shoe towards the rear and remove the spreader bar. Set it with the other parts. Grip the adjuster spring on the bottom and push it towards the front or rear to remove it. Pull the brake adjuster, making note of its orientation. Rotate the adjuster to collapse it completely. Set it aside. Slide the adjuster lever forward to remove it from the pivot and pull the spring off. Set these aside. Pivot the parking brake arm out of the primary shoe and allow it to hang.
15. Spray the parts you have removed and set aside thoroughly with the brake cleaning fluid. Don’t spray the parts you put into the dust cap. Liberally spray the backing plate with the cleaning fluid. Coat the two raised nubs at the front and rear of the backing plate with the white lithium grease.
16. Insert the tab into the proper opening on the replacement primary shoe. Attach the two shoes to the backing plate by sliding the retaining pins through the backing plate holes and installing the retaining springs and caps. Align the tab on the pin and the slotted keyway on the caps, push in and turn one quarter-turn.
17.Place the diamond-shaped spacer over the center stud. Place the eyelet on the adjuster cable over the center stud. Place the adjuster cable slider/ anchor plate into the proper hole.
18. Paying attention to orientation, insert the short, curled ends of the return springs into the proper holes and using the cupped arm of the return spring tool, pull the hooked ends of the springs over the center stud. Squeeze the hook ends together. Replace the shoe spreader bar, paying attention to orientation.
19. Slide the adjuster spring over the pivot arm. Slide the adjuster arm over the pivot arm and slide it towards the rear to lock it in place. Route the adjuster cable around the slider/anchor and clip the end of the adjuster cable to the adjuster arm.
20. Pull the rear shoe towards the rear and insert the adjuster, paying attention to orientation. Slide the brake drum over the hub spindle.
21. Reassemble the hub in the following order: bearing (tapered end towards inside), thrust washer, tab pointing down into slot in spindle and lock nut. Tighten the lock nut to approximately 10 to 15 foot-pounds. Slide the castellated cover over the nut. Insert the cotter pin and bend the ends around.
22. Repeat steps 6 through 15 above on the other side.
23. Replace the wheels by aligning the studs with the holes in the wheels and install the lug nuts by turning them clockwise by hand. Snug the lug nuts with the lug wrench.
Repeat the above two steps on the other side.12. Remove the two return springs by placing the rounded opening of the brake return spring over the top center stud and turning it counterclockwise, while pushing towards the backing plate. Remember how these springs were oriented and set them aside. Repeat this process on the other side.
25. Lift the van off the jack stands one side at a time and lower that each side until the wheel just makes contact with the ground. Tighten the lug nuts with the lug wrench to 50 to 60 foot-pounds. Lower the vehicle to the ground. Do this on the other side. Slide a jack stand under the frame and carefully lower the van onto the jack stand. Repeat this process on the opposite side. Remove the lug nuts from both sides and set them and the wheels aside.
