The 2009 Grand Caravan brake system shows a pattern of accelerated wear and component failure starting well below industry norms. Owners report rear brake calipers seizing repeatedly, with some vehicles requiring caliper replacement three times by 121,000 miles. The driver's side rear is most often the problem. Calipers stick, causing wheels to overheat—water vaporizes on contact—and brake fluid to boil. Front rotors warp as early as 9,000 miles despite light use, with vibration and shaking when braking. Some owners describe rotors warping every 15,000 miles. Rear brake pads wear unevenly and critically by 12,000–34,000 miles, far shorter than typical 40,000–50,000 mile life. Brake dust appears excessive as early as 7,500 miles. Owners also report brake unresponsiveness when cruise control is active, requiring hard pedal pressure to stop. One dealer acknowledged a design flaw in heat retention; another noted tight bracket clearance causing pads to stick in slides. Chrysler issued an extended warranty for front brakes but denies the rear brake failures are defects, claiming 15–20,000 miles is normal wear for this model.
Failure modes owners describe
Rear brake caliper seizing and sticking
Rear brake calipers stick or seize, causing brakes to lock and wheels to overheat, smoke, and smell of burning rubber. Driver's side rear caliper is most frequently affected. Issue recurs even after multiple caliper replacements.
When: As early as 15,000 miles; recurring at 68,000, 98,000, and 121,000 miles on some vehicles
Symptoms owners cite: Rear wheel or brake assembly smoking; Brake assembly and wheel extremely hot (water vaporizes on contact); Screeching or squealing sound from brakes; Burning rubber smell; Reduced fuel economy; Brake pad wear down to metal in 11,000–15,000 miles on affected side; Wheel unable to rotate freely due to brake drag
Repairs/costs cited: Rear caliper replaced multiple times (two to three replacements on some vehicles) with no permanent fix; brake line replaced once on one vehicle; one complaint mentions brake bracket/clip redesign by Chrysler with additional clearance on national backorder
Recalls/TSBs owners mention: Extended warranty issued for front brakes only; rear brake issues characterized as normal wear; Chrysler stated 15–20K miles normal wear life for rear brakes on this model; some consumers report Chrysler paid for bracket replacement, potentially admitting fault but limiting assistance to parts only
Warped or pitted front rotors
Front rotors warp, pit, or become discolored from overheating well before expected service intervals. Warping occurs independently of pad wear in some cases. Dealers attribute this to design flaw in heat retention of front brake assembly.
When: 1,700 miles to 44,000 miles; as soon as 9,000 miles on some vehicles; recurrence within 8,000–15,000 miles after repair
Symptoms owners cite: Severe vibration or pulsation when braking at 40–100 mph; Steering wheel shaking during braking; Brake pedal pulsates; Rotors discolored (black or blue from excessive heat) even with low mileage; Rotors pitted or rusted
Repairs/costs cited: Rotors replaced or turned (resurfaced) multiple times on individual vehicles; one dealer stated to expect this repair every 15,000 miles as a 'design flaw'; front rotors sometimes replaced under TSB with $100 deductible; replacement parts on backorder for 3 weeks in one case
Recalls/TSBs owners mention: Extended warranty issued for front brakes covering premature wear on pads and rotors; TSB issued allowing repairs under warranty with deductible; one complaint mentions notice from Chrysler of extended warranty because 'pads and rotors might need replacement earlier than expected'; one owner states Chrysler offered no assistance after VIN initially deemed not part of affected vehicles
Rear brake pad premature wear and sticking in slides
Rear brake pads wear prematurely and unevenly; inside pads wear faster than outside pads on the same wheel. Pads stick in bracket slides due to insufficient clearance, causing dragging and accelerated wear. Brake dust and corrosion contribute to sticking.
When: As early as 7,500 miles (excessive brake dust observed); critical wear by 12,000–34,000 miles
Symptoms owners cite: Brake dust excessive on rear wheels starting around 7,500 miles; Inside brake pads wear to wear indicator while outside pads at 50% remaining; Left and right rear rotors wear at significantly different rates; Brake pad wear down to metal-on-metal contact; No warning wear indicator on original pads; Dragging brakes reducing fuel economy
Repairs/costs cited: Brake pads replaced every 11,000–15,000 miles on affected vehicles; rotors also require replacement or resurfacing when pads wear; one dealer noted brake bracket/clip clearance is too tight and supplied redesigned bracket; adapter added in at least one case to correct uneven pad wear
Recalls/TSBs owners mention: Extended warranty issued for front brakes only; rear brake failures characterized as normal wear; Chrysler stated 15–20K miles is normal wear expectancy for rear brakes; one complaint notes Chrysler paid for bracket replacement, suggesting acknowledgment of defect but limited compensation
Brake system unresponsiveness or failure with cruise control
Brakes fail to respond when pedal is first depressed while cruise control is active. Requires hard or repeated pedal pressure to engage braking. Brake warning light illuminates and remains for 2–3 minutes before extinguishing.
When: During cruise control operation at various speeds (45–75 mph)
Symptoms owners cite: Brake pedal depressed but brakes do not respond initially; Requires jamming or second hard depression of brake pedal; Brake warning light illuminates and stays on for 2–3 minutes; Loud abnormal noise from engine heard in at least one incident; Vehicle continued to accelerate in one case despite attempted braking and cruise cancel attempts
Repairs/costs cited: One consumer taken to dealer five times (Feb–Aug 2010, then Aug 2011) for diagnosis and repair without resolution; dealers replaced multiple parts without identifying root cause; no repairs completed on record for some complaints
Recalls/TSBs owners mention: No manufacturer response documented in the narratives for this issue
Engine racing and brake system malfunction together
Engine revs uncontrollably while brake pedal is pressed and held hard. Skid protection light and brake warning light both illuminate. Brakes heat up severely but vehicle stops. Engine does not respond to cruise control cancel or on/off switch until ignition is shut off.
When: Single incident reported during attempted passing maneuver on highway at speed
Symptoms owners cite: Engine speed increases uncontrollably during attempted passing; Brake pedal depression does not prevent acceleration; Cruise control on but not activated; attempted cancel unsuccessful; Skid protection light and brake warning light both illuminate; Brakes overheat; Engine will not stop revving or lights reset until ignition shut down
Repairs/costs cited: Vehicle towed to dealer; no repair details provided in complaint
Recalls/TSBs owners mention: No manufacturer response documented in the narratives
Synthesized from 44 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.