ION, L-Series, S-Series 1999-2005

Brake Pads

Print

Removal & Installation




CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Remove the rear wheels.
  2.  
  3. Remove the caliper lock and guide pins.
  4.  
  5. Remove the caliper from the support, being careful not to damage the pin boots and suspend the caliper from a wire.
  6.  
  7. Remove the brake pads from the support.
  8.  

To install:

  1. Using SA91110NE piston driver tool, bottom the piston by rotating it clockwise into the caliper bore; do not use a C-clamp to press the piston into the bore.
  2.  
  3. Align the piston slots so they are perpendicular to the brake pads.
  4.  
  5. Carefully lift the inner edge of the piston boot to release any trapped air. The boot must lie flat below the level of the piston face.
  6.  
  7. Install new pad clips into the caliper support.
  8.  
  9. Install the inner and outer brake pads into the clips on the support. The pad with the wear sensor should be located outboard. The piston indentation slots should be positioned to correctly accept the brake pads.
  10.  
  11. Position the caliper body onto the support. Lubricate the non-threaded portion of the guide and lock pins, then install the pins and torque to 27 ft. lbs. (36 Nm).
  12.  
  13. Check the position of the pad clips. If necessary, use a small suitable tool to re-seat or center the pad clips on the support. Repeat the procedure for the opposite side brake pads.
  14.  
  15. Install the rear wheel assemblies.
  16.  
  17. Prior to operating the vehicle, depress the brake pedal a few times until the brake pads are seated against the rotor.
  18.  


CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Inspect the fluid level in the brake master cylinder auxiliary reservoir.
  2.  
  3. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
  4.  
  5. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Remove the tire and wheel assembly.
  10.  
  11. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub.
  12.  
  13. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
    NOTE
    When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 in) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism.

  14.  
  15. Tighten the C-clamp just enough to compress the caliper piston 0.039 inches (1 mm) of travel only.
  16.  
  17. Remove the C-clamp from the caliper.

    Click image to see an enlarged view

    Fig. While using a wrench on the flats of the caliper guide pins (1), remove the brake caliper guide pin bolts (2)

  18.  
  19. While using a wrench on the flats of the caliper guide pins, remove the brake caliper guide pin bolts.
    NOTE
    Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

  20.  
  21. Without disconnecting the hydraulic brake flexible hose, remove the caliper from the mounting bracket and secure the caliper with heavy mechanics wire, or equivalent.

    Click image to see an enlarged view

    Fig. Remove the brake pads from the caliper mounting bracket

  22.  
  23. Remove the brake pads from the caliper mounting bracket.
  24.  
  25. Remove the brake pad retainers from the caliper bracket.
  26.  
  27. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket (2), of any debris and corrosion.
  28.  
  29. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

    Restricted caliper guide pin movement
     
    Looseness in the brake caliper mounting bracket
     
    Seized or binding caliper guide pins
     
    Split or torn boots
     

  30.  
  31. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.
  32.  
  33. Using a spanner wrench type caliper piston installer, fully retract the piston into the caliper bore.
  34.  

To install:

  1. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket (2) only.
  2.  
  3. Install the brake pad retainers (1) to the brake caliper bracket.
    NOTE
    The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the bottom of the pad when installed in vehicle position.

  4.  
  5. Install the brake pads to the caliper bracket.
  6.  
  7. Remove the support, and install the caliper into position over the disc brake pads and to the caliper mounting bracket.
  8.  
  9. While using a wrench on the flats of the caliper guide pins, install the brake caliper guide pin bolts, and tighten the bolts to 25 ft. lbs. (34 Nm).
  10.  
  11. Remove the wheel nuts retaining the brake rotor to the hub.
  12.  
  13. Install the tire and wheel assembly.
  14.  
  15. Lower the vehicle.
  16.  
  17. With the engine OFF , gradually apply the brake pedal approximately two-thirds of its travel distance.
  18.  
  19. Slowly release the brake pedal.
  20.  
  21. Wait 15 seconds, then gradually apply the brake pedal approximately two-thirds of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
  22.  
  23. Fill the master cylinder auxiliary reservoir to the proper level.
  24.  
  25. Burnish the pads and rotors.
  26.  

  1. Remove the rear wheels.
  2.  
  3. Remove the caliper lock and guide pins.
  4.  
  5. Remove the caliper from the support, being careful not to damage the pin boots and suspend the caliper from a wire.
  6.  
  7. Remove the brake pads from the support.
  8.  

To install:

  1. Using SA91110NE piston driver tool, bottom the piston by rotating it clockwise into the caliper bore; do not use a C-clamp to press the piston into the bore.
  2.  
  3. Align the piston slots so they are perpendicular to the brake pads.
  4.  
  5. Carefully lift the inner edge of the piston boot to release any trapped air. The boot must lie flat below the level of the piston face.
  6.  
  7. Install new pad clips into the caliper support.
  8.  
  9. Install the inner and outer brake pads into the clips on the support. The pad with the wear sensor should be located outboard. The piston indentation slots should be positioned to correctly accept the brake pads.
  10.  
  11. Position the caliper body onto the support. Lubricate the non-threaded portion of the guide and lock pins, then install the pins and torque to 27 ft. lbs. (36 Nm).
  12.  
  13. Check the position of the pad clips. If necessary, use a small suitable tool to re-seat or center the pad clips on the support. Repeat the procedure for the opposite side brake pads.
  14.  
  15. Install the rear wheel assemblies.
  16.  
  17. Prior to operating the vehicle, depress the brake pedal a few times until the brake pads are seated against the rotor.
  18.  

  1. Inspect the fluid level in the brake master cylinder auxiliary reservoir.
  2.  
  3. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
  4.  
  5. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Remove the tire and wheel assembly.
  10.  
  11. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub.
  12.  
  13. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
    NOTE
    When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 in) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism.

  14.  
  15. Tighten the C-clamp just enough to compress the caliper piston 0.039 inches (1 mm) of travel only.
  16.  
  17. Remove the C-clamp from the caliper.

    Click image to see an enlarged view

    Fig. While using a wrench on the flats of the caliper guide pins (1), remove the brake caliper guide pin bolts (2)

  18.  
  19. While using a wrench on the flats of the caliper guide pins, remove the brake caliper guide pin bolts.
    NOTE
    Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

  20.  
  21. Without disconnecting the hydraulic brake flexible hose, remove the caliper from the mounting bracket and secure the caliper with heavy mechanics wire, or equivalent.

    Click image to see an enlarged view

    Fig. Remove the brake pads from the caliper mounting bracket

  22.  
  23. Remove the brake pads from the caliper mounting bracket.
  24.  
  25. Remove the brake pad retainers from the caliper bracket.
  26.  
  27. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket (2), of any debris and corrosion.
  28.  
  29. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

    Restricted caliper guide pin movement
     
    Looseness in the brake caliper mounting bracket
     
    Seized or binding caliper guide pins
     
    Split or torn boots
     

  30.  
  31. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.
  32.  
  33. Using a spanner wrench type caliper piston installer, fully retract the piston into the caliper bore.
  34.  

To install:

  1. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket (2) only.
  2.  
  3. Install the brake pad retainers (1) to the brake caliper bracket.
    NOTE
    The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the bottom of the pad when installed in vehicle position.

  4.  
  5. Install the brake pads to the caliper bracket.
  6.  
  7. Remove the support, and install the caliper into position over the disc brake pads and to the caliper mounting bracket.
  8.  
  9. While using a wrench on the flats of the caliper guide pins, install the brake caliper guide pin bolts, and tighten the bolts to 25 ft. lbs. (34 Nm).
  10.  
  11. Remove the wheel nuts retaining the brake rotor to the hub.
  12.  
  13. Install the tire and wheel assembly.
  14.  
  15. Lower the vehicle.
  16.  
  17. With the engine OFF , gradually apply the brake pedal approximately two-thirds of its travel distance.
  18.  
  19. Slowly release the brake pedal.
  20.  
  21. Wait 15 seconds, then gradually apply the brake pedal approximately two-thirds of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
  22.  
  23. Fill the master cylinder auxiliary reservoir to the proper level.
  24.  
  25. Burnish the pads and rotors.
  26.  

 
label.common.footer.alt.autozoneLogo