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Discussion Starter · #1 ·
So we all know by now that the '12+ vans have either an HD brake option or come standard. The earlier models had the smaller 302mm front rotors, with a single piston caliper. The HD brakes come with 330mm rotors, with dual piston calipers. Much improved.

I ordered all parts from Rock Auto, using a 2013 van with HD brake option in the parts catalog. I got 2 Cardone reman calipers w/brackets, 2 Raybestos Advanced Technology rotors, and a set of Raybestos Professional grade pads. $465 shipped to my neck of the woods.

Here's a shot of the passenger side before I started.



Got the drivers side wheel, caliper, and rotor off.



A shot of the size difference between the old caliper and the new one. New one is on the left, old is on the right. HUGE difference in weight. Looks like the new caliper two of the same size piston of the old one.



A shot of the differences in right and left. The bleeder valve needs to be above the banjo bolt for proper bleeding.



Continues in next post...
 

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Discussion Starter · #2 ·
Old Chrysler rotor came off. Note the pentastar logo stamp. These things are JUNK.



Since ours is a 2010, but with factory 17" wheels, I had to do a test fit of the wheel before continuing. Perfect fit.



New rotor and bracket installed on the passenger side.


Another shot. These brakes are similar to what you'd find on a full size truck.


All done!


My two concerns about this job was 1) Would my 2010 17" factory wheels fit? 2) How would pedal feel turn out?

In the end the brakes feel about the same as they did before. The pedal travel is about the same as before. Generally, after a brake job, more material is present on the pads so the piston travel (and ultimately pedal travel also) is shorter. The pads I took off were about 50% gone.

The main test here was the wifey: She loved them, and said nothing about the pedal travel.

In the end, a win all the way around. I would definitely recommend this to anyone who has the skill and tools to do the job.

Tools needed:
10mm box end wrench (brake bleeder)
14mm socket / box end wrench (caliper slide bolts)
21mm socket / box end wrench (caliper bracket bolts)
3/4" tire iron (lug nut removal)
One man brake bleeder kit or an assistant to help you bleed the calipers.
1 can brake cleaner (optional)
1 can brake fluid
Jack / vehicle lift
 

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very helpful for someone interested in this conversion...I cant believe the difference in caliper size!
 
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Good to hear this upgrade went so easily for you and that you were able to use your factory wheels.
On mine the HD brakes are VERY responsive.
I’m curious to know how things work out in the long run since on a factory HD setup the rears brakes and master cylinder are larger?
 

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2 questions:

1) Does backing plate need change also to meet larger rotor?

2) Is HD master cylinder has same part # as regular one?
 

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Thanks! Those look much better!

The 17" wheels that you have on your 2010 are still being used on the 2011+ Crew models, so you were good to go there.

When these pads or rotors go, I want to look for a set of the new 17" rims and do the HD brake upgrade to ours.
 

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im thinking the pedal might have the same feel as before because the procedure was not performed on the rears?....is that in your plans?....or cost prohibitive?.....
 

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Outstanding write-up Ben!

I had no idea the bigger brakes were a plug-n-play option (provided you've got 17" wheels!).

That's the way to go if a major brake job is needed.
 

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Discussion Starter · #10 ·
2 questions:

1) Does backing plate need change also to meet larger rotor?

2) Is HD master cylinder has same part # as regular one?
1). I didn't change mine, I did have to push them out of the way a bit. Really minor thing, though.

2). The MC is different for the HD brakes. I wanted to test the fronts and see how they felt before going through the effort of swapping it. They are a pain to bleed because you could introduce air into the lines very easy at an upstream point in the system.
 

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Discussion Starter · #11 ·
im thinking the pedal might have the same feel as before because the procedure was not performed on the rears?....is that in your plans?....or cost prohibitive?.....
I put new rotors and pads on the rear about six months ago... So they don't need to be changed out yet. If we have the van long enough, I will definitely put the bigger ones on the rear also.
 
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This. Is. Awesome!

I am more than a little bit surprised that the bolt pattern is the same for the two caliper assemblies.

1) I'll assume that the vans with 16" wheels have the same brakes at the vans with 17' wheels....

2) How about posting the part numbers to further make it easier!


Thx.
 

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This. Is. Awesome!

I am more than a little bit surprised that the bolt pattern is the same for the two caliper assemblies.

1) I'll assume that the vans with 16" wheels have the same brakes at the vans with 17' wheels....

2) How about posting the part numbers to further make it easier!


Thx.
Since these vehicle were being built side by side in the factory with standard and HD brakes Chrysler keep it simple by using the same steering knuckles, hence the same caliper adapter bolt pattern.

Here is a link to a thread with the Chrysler PN's
http://forum.chryslerminivan.net/showthread.php/40865-Early-2012s-still-have-brake-issues/page5
 

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A shot of the size difference between the old caliper and the new one. New one is on the left, old is on the right. HUGE difference in weight. Looks like the new caliper two of the same size piston of the old one.

I'm kind of disappointed that you didn't really notice a difference. Just looking at that picture, it seems as if you should be able to tap the brakes and stop so fast that you move backwards through time.
 

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Discussion Starter · #19 ·
I'm kind of disappointed that you didn't really notice a difference. Just looking at that picture, it seems as if you should be able to tap the brakes and stop so fast that you move backwards through time.
You may have misread my initial post. I was concerned about pedal effort and feel, not so much how much better the van would stop. That was a given. ;)

I did notice a difference between the two concerning stopping force. These are considerably better. So much so i got a little dizzy when i made a panic stop from about 65 mph to 0!
 

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Discussion Starter · #20 ·
This. Is. Awesome!

I am more than a little bit surprised that the bolt pattern is the same for the two caliper assemblies.

1) I'll assume that the vans with 16" wheels have the same brakes at the vans with 17' wheels....

2) How about posting the part numbers to further make it easier!


Thx.

I didn't get these parts from the dealer, since I try to avoid Chrysler rotors if at all possible. My stuff came from Rockauto.

Pads:
RAYBESTOS Part # PGD1589C Professional Grade - Ceramic
Front; OE Pad Material is Ceramic; 330mm Rotor Diameter

Rotors: (2)
RAYBESTOS Part # 780964 Advanced Technology
Front; 330mm Rotor Diameter

Caliper:
A-1 CARDONE Part # 18B5402 Reman. A-1 CARDONE Friction Choice Caliper w/Bracket & Installation Hardware (Driver's side)
A-1 CARDONE Part # 18B5403 Reman. A-1 CARDONE Friction Choice Caliper w/Bracket & Installation Hardware (Passenger side)
 
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