Brake Pad: Service and Repair

Saturn replacement brake lining material is recommended to maintain the balance between front and rear brake performance. Saturn replacement brake parts have been carefully selected to provide proper brake balance for purposes of both stopping distance, and control over a full range of operating conditions. Installation of front or rear brake lining material other than Saturn replacement parts, can change the intended brake balance of the vehicle.
When installing new front brake pads or when servicing front disc brakes, remove all rust and corrosion from the caliper brackets and the spring clips. If reinstalling used brake pads, remove all rust and corrosion from the ends of the brake pads and from the notch. Make sure the brake pads move freely in the caliper brackets when the brakes are assembled.


REMOVAL

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE ADDITIONAL SUPPORT TO THE OPPOSITE END OF THE VEHICLE THAT COMPONENTS WILL BE REMOVED FROM.





1. Raise vehicle on hoist.
2. Remove front road wheels
3. Remove (3) caliper lock pin.
4. Pivot caliper body up, around guide pin.





5. Remove inboard and outboard brake pads from caliper support.





6. Measure the lining thickness with a steel rule.

Note: Measurement is of lining material only, and does not include the backing plate.

Discard Thickness: 2.0 mm (0.080 inch)
Replace front pads as a set if any pad has a thickness at or less than the Discard Thickness, or if any pad has severe, uneven wear.





7. Remove two pad clips from caliper support.
8. Inspect:
a. Lock pin and guide pin boots for deterioration. If damaged, replace.
b. Piston boot for deterioration. If damaged, overhaul the caliper.
c. Lock pin for damage or corrosion. Replace if damaged or corroded (do not attempt to clean away corrosion).
9. Repeat steps 3 through 7 for opposite side.

INSTALLATION

IMPORTANT: Never replace brake pads on one side of axle only. Left and right side brake pads must be replaced only as axle sets.





1. Using a C-clamp, bottom the piston back into the caliper bore.

IMPORTANT: Boot must lie flat, below the level of the piston face.





2. Lift inner edge of piston boot to release any trapped air.

IMPORTANT: Remove rust and corrosion from caliper brackets and spring clips. If reusing brake pads, remove rust and corrosion from the ends of the brake pads. Be sure to install reused pads in their original positions. Using Molykote grease, apply lubricant to the four notched areas of the caliper bracket. The lubricant should be applied to the caliper brackets behind the spring clips, and the spring clip-to-brake pad interfaces.





3. Install new pad clips into caliper support.

NOTICE: Install the linings so the wear sensors are at the top of the caliper bracket. When the linings are installed properly, forward rotation of the rotor will first pass the sensor and then the lining.





4. Install inner and outer brake pads into caliper support.
5. Pivot caliper body about guide pin, onto the caliper support.

NOTICE: Be careful not to damage lock pin boot.

IMPORTANT: Compress pin boots by hand as caliper moves into position.





6. Lubricate straight section (not threads) of lock pin with silicone grease.
7. Install pin through caliper body into caliper support and torque to specification.
Torque: 36 Nm (27 ft. lbs.)

NOTICE: Make sure lock pin boot is properly positioned before installing lock pin, or boot damage may occur.

IMPORTANT: Check position of pad clips. If necessary, use a small screw driver to re-seat or center the pad clips on the support. Make sure brake pads move freely in the caliper bracket. Make sure caliper moves freely on the guide and lock pins.





8. Repeat steps 1 through 7 for opposite side.

NOTICE: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors/drums. Failure to do so can cause wheel nuts to loosen in service.

9. Position wheel onto hub.
10. Install wheel nuts and tighten in a crisscross pattern. Repeat tightening pattern to be sure torque is correct.
Torque: 140 Nm (103 ft. lbs.)
11. Lower vehicle from hoist.

CAUTION: IF THIS OPERATION IS NOT CARRIED OUT, BRAKES WILL NOT OPERATE DURING INITIAL BRAKE APPLICATIONS.

12. Prior to operating vehicle, depress the brake pedal several times until brake pads are fully seated against rotor.