This is going to be unnecessarily expensive due to ignoring the symptoms for so long. By the time the grinding first started, the brakes were long overdue for an inspection. What has likely happened is the metal-on-metal grinding has worn the brake rotor down so far, the piston fell out of the caliper. Since that brake can no longer apply, you're not hearing the grinding. That also explains the leaking brake fluid. The right front and the left rear are the only brakes still working, but those are going to quit too once enough brake fluid is lost. At that point there will be no brakes except for the parking brake.
The next problem is you'll very likely need a replacement master cylinder. Over time, crud and corrosion build up in the lower halves of the bores where the pistons don't normally travel. When the brake pedal is pushed more than halfway to the floor, either due to a leaking flexible hose or steel line, improper bleeding procedures, or in this case, a caliper that fell apart, the pistons get run over that crud. That can rip the rubber lip seals. That causes a slowly-sinking brake pedal, and that often takes two or three days to show up. Once you mention the brake pedal went to the floor, many shops will automatically include a rebuilt master cylinder in their repair estimates. This doesn't apply to a master cylinder that's less than about a year old. That isn't enough time for that corrosion to develop yet.
Brake calipers can be rebuilt, in fact, we did that with almost every brake job in the 1980s, but today professionally rebuilt calipers are relatively inexpensive and are the better value. You'll need both front calipers so they're matched and provide balanced stopping power. Also plan on the normal stuff, meaning pads and rotors. If the van has anti-lock brakes and the master cylinder runs out of brake fluid, a scanner is usually needed to bleed the hydraulic controller. If the van doesn't have anti-lock brakes, or the reservoir isn't allowed to run empty, standard bleeding procedures will suffice.
If you want to pursue this yourself, start by looking at these articles:
https://www.2carpros.com/articles/guide-to-fixing-automotive-brake-grinding-causes-and-solutions
https://www.2carpros.com/articles/brake-caliper-replacement
https://www.2carpros.com/articles/how-to-replace-a-brake-master-cylinder
https://www.2carpros.com/articles/how-to-replace-front-brake-pads-and-rotors-fwd
https://www.2carpros.com/articles/brake-pedal-goes-to-the-floor
Let me know your level of expertise too. I have some tricks that will make the job a little easier. There's a lot of things you can do to end up with a better quality brake job, and a number of things to avoid to prevent other problems. I'll gladly share that wondrous information with you.
Check out this video too:
https://youtu.be/9S0im10Z2T0
They show replacing pads and rotors on a PT Cruiser. The calipers might mount differently, but the procedure will be very similar. Let me know how you'd like to proceed.
Jun 13, 2023 at 5:38 PM