Brakes do not release

INFIDEL

MEMBER
2008 DODGE CARAVAN
3.3L
V6
2WD
AUTOMATIC
100,000 MILES

I bought this van with about 18,000 miles on it. At first all was good, but around 65,000 miles, I started having brake issues. I replaced the pads, and the one's on 2 wheels burnt up. Left front, right rear, if memory serves me. I replaced the pads, and replaced all four calipers, with reman. Again burnt pads up. Tried changing calipers again, this time with all new hoses. Same problem.
The brakes would release (maybe), and you can drive normally. But, eventually they would lock a wheel or two back up, and you couldn't get them to release. I think I've had six sets of calipers and hoses, along with pads on this POS (I'll never own another Chrysler product). I don't use this van much anymore, except for hauling stuff I don't want in my Toyota Sienna.
I will admit to driving harder when the brakes stick, in hopes this thing will burn up. Don't you love the smell of brake pads burning in the morning?
I'm back to stuck brakes again, and at my wits end with this piece of crap.
Any help would be appreciated.
I guess I didn't read the warning on the van, it said Dodge, obviously that means step aside and don't buy it!

5 Replies

CARADIODOC

MECHANIC
33,873 POSTS

Funny. My cousin dumped his Sienna and is driving a Caravan now.

The first step is to actually diagnose the cause of this problem, not just throw parts at it. When this occurs again, park on a slight incline, place a block a few inches downhill of one tire, shift to "neutral", then open the hydraulic system in various places to see what lets the brakes release.

You had a dandy observation that a front brake and the opposite rear brake lock at the same time. Most front-wheel-drive vehicles use a split-diagonal hydraulic system that pairs the opposite corners in each of the two hydraulic systems. What worries me is that two brakes are locking at the same time. That tends to rule out a caliper in favor of what both brakes have in common. That's the master cylinder.

Where I would start with opening the hydraulic system is to loosen the steel lines right at the master cylinder. If that lets the brakes release, there's one of two causes. One is something happened to the bracket for the brake light switch and the switch is holding the brake pedal down a little. My worry is the second possibility. That's brake fluid contaminated with a petroleum product. That will cause the internal rubber lip seals to swell and grow past the fluid return ports, blocking them. As the brakes drag and heat up, that heat migrates into the brake fluid causing it to expand. Since it's trapped and can't return to the reservoir, the expanding fluid applies the brakes even harder, and more heat is generated.

If loosening the lines at the master cylinder don't let the brakes release, we can breathe a sigh of relief. Next would be to crawl underneath and open the bleeder screws on the calipers. If they still don't release, the best suspect is the mounting hardware has rust pits or a slide bolt is bent causing the caliper to not release properly.

Does your van have anti-lock brakes?