Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION



Front Disc Brakes

See Figures 1, 2, 3 and 4

  1. Raise the front of the vehicle and support it safely using jackstands, then remove the front wheel.
  2.  
  3. Disconnect the brake hose from the caliper. Plug the openings to prevent excessive fluid contamination or loss.
  4.  
  5. Remove the lock pin and guide pin from the caliper and support.
  6.  
  7. Remove the caliper from the support, being careful not to damage the pin boots. Remove the pin boots from the caliper support and inspect for damage.
  8.  

To install:
  1. Make sure the piston is bottomed in the bore. If necessary, bottom the piston by hand or by using a C-clamp.
  2.  
  3. If removed, install the brake pads to the caliper support.
  4.  
  5. Lubricate the pin boots and guide pins with silicone grease. If removed, install the pin boots into the caliper support.
  6.  
  7. Position the caliper onto the support and over the brake pads, then lubricate the non-threaded portion of the guide and lock pins with silicone grease. Install the pins and tighten to 27 ft. lbs. (36 Nm).
  8.  
  9. Make sure the brake line is properly routed with a loop to the rear, then install the brake hose with new washers. Tighten the fitting to 36 ft. lbs. (49 Nm).
  10.  
  11. Properly bleed the hydraulic brake system.
  12.  
  13. Install the wheel, then remove the supports and carefully lower the vehicle.
  14.  



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Fig. Fig. 1: Remove the retainer and disconnect the brake hose from the caliper



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Fig. Fig. 2: Remove the guide and lock pins, then remove the caliper from the support. Remove and inspect the pin boots



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Fig. Fig. 3: Lubricate and install the pin boots into the caliper support



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Fig. Fig. 4: The brake hose must be properly routed with its loop towards the rear of the vehicle

Rear Disc Brakes

See Figures 5, 6 and 7

  1. Raise the rear of the vehicle and support it safely using jackstands, then remove the rear wheel.
  2.  
  3. Disconnect the brake hose from the caliper. Plug the openings to prevent fluid contamination or loss.
  4.  
  5. Slip the end of the parking brake cable off the parking brake lever, then remove the cable outer housing from the cable bracket with SA9151BR, or an equivalent cable release tool.
  6.  
  7. Remove the lock pin and guide pin.
  8.  
  9. Remove the caliper from the support, being careful not to damage the pin boots. If necessary, remove the pin boots from the caliper support.
  10.  
  11. Inspect the piston and pin boots for deterioration and the pins for corrosion. Damaged boots must be replaced; if the piston boot is damaged, the caliper must be overhauled. Corroded pins must be replaced; do not attempt to remove the corrosion.
  12.  

To install:
  1. Make sure the piston is bottomed in the bore. Do not compress the piston using a C-clamp; instead, the piston must be rotated into the caliper on its threads using a piston driver tool.
  2.  
  3. If removed, install the brake pads to the caliper support.
  4.  
  5. Lubricate the pin boots and guide pins with silicone grease. If removed, install the pin boots into the caliper support.
  6.  
  7. Position the caliper, then lubricate the non-threaded portion of the guide and lock pins. Install the pins and tighten to 27 ft. lbs. (36 Nm).
  8.  
  9. Install the brake hose with new washers, then tighten the fitting to 36 ft. lbs. (49 Nm).
  10.  
  11. Connect the parking brake cable.
  12.  
  13. Properly bleed the hydraulic brake system.
  14.  
  15. Install the wheel, then remove the supports and lower the vehicle.
  16.  
  17. Prior to operating the vehicle, depress the brake pedal a few times until the brake pads are seated against the rotor and a firm pedal is felt. For safety's sake, DO NOT ATTEMPT TO MOVE THE VEHICLE UNTIL THIS STEP IS PERFORMED.
  18.  



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Fig. Fig. 5: Remove the retainer, then disconnect the brake line and washers from the caliper



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Fig. Fig. 6: The parking brake cable attaches to the rear of the caliper/support assembly



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Fig. Fig. 7: Disconnect the parking brake cable end

OVERHAUL



See Figures 8 through 15

Some vehicles may be equipped with dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.

      Click image to see an enlarged view

      Fig. Fig. 8: For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



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      Fig. Fig. 9: Withdraw the piston from the caliper bore

    4.  

  2.  
  3. For the second method, you must rotate the piston to retract it from the caliper.
  4.  
  5. If equipped, remove the anti-rattle clip.
  6.  



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Fig. Fig. 10: On some vehicles, you must remove the anti-rattle clip

  1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  2.  



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Fig. Fig. 11: Use a prytool to carefully pry around the edge of the boot ...



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Fig. Fig. 12: ... then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  



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Fig. Fig. 13: Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To assemble:
  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
  6.  
  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  



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Fig. Fig. 14: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Install the caliper in the vehicle.
  2.  
  3. Install the wheel and tire assembly, then carefully lower the vehicle.
  4.  
  5. Properly bleed the brake system.
  6.  



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Fig. Fig. 15: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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