Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Brake Pads

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REMOVAL & INSTALLATION



Front Disc Brakes

See Figures 1 through 8

Always replace the brake pads in sets, meaning BOTH front wheels.

  1. Raise the front of the vehicle and support it safely using jackstands, then remove the front wheels.
  2.  
  3. Remove the lower caliper lock pin.
  4.  

The Saturn brake pad replacement procedure states that after removing the lower caliper pin, you can simply pivot the caliper to a vertical position in order to remove the brake pads. This procedure, when attempted on a 1992 SC with ABS, looked as if it would place excessive stress on the brake line. No changes in steering position seemed to alleviate this tension, so a full pivot for pad removal was not attempted. Another option is to remove the upper caliper pin, but not the lower pin, and simply pivot the caliper down for possible access. However, to prevent damage to the brake line you may wish to remove both guide pins and support the caliper assembly from the strut using a coat hanger or length of wire.

  1. Pivot the caliper up or down on either guide pin or remove both guide pins and support the caliper from the strut using a coat hanger or length of wire.
  2.  
  3. Remove the 2 brake pads and the pad clips from the caliper support Discard the old pad clips.
  4.  
  5. Check the caliper pins, pin boots and the piston boot for deterioration or damage.
  6.  

To install:
  1. Either by hand or using a C-clamp, bottom the piston all the way into the caliper bore.
  2.  
  3. Carefully lift the inner edge of the piston boot by hand to release any trapped air.
  4.  
  5. Install new pad clips into the caliper support.
  6.  
  7. Install the inner and outer brake pads into the support. If installed, remove the temporary support wire from the caliper.
  8.  
  9. Pivot or position the caliper body on the upper guide pin into position. Compress the boots by hand as the caliper is positioned onto the support.
  10.  
  11. Lubricate the smooth ends of the lock and guide pins with silicone grease, then install the pin and tighten to 27 ft. lbs. (36 Nm). Do not get grease on the pin threads.
  12.  
  13. Repeat the procedure for the opposite side brake pads.
  14.  



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Fig. Fig. 1: Loosen the caliper lower lock pin



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Fig. Fig. 2: Remove the lock pin, being careful not to damage the boot



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Fig. Fig. 3: Loosen and remove the upper guide pin from the caliper



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Fig. Fig. 4: If removed, support the caliper from the strut using wire or a coat hanger

  1. Install the front wheels, then remove the supports and carefully lower the vehicle.
  2.  
  3. 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.
  4.  



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Fig. Fig. 5: Remove the brake pads from the caliper support bracket



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Fig. Fig. 6: Remove and discard the old brake pad retaining clips from the support bracket



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Fig. Fig. 7: If necessary, use a C-clamp to bottom the caliper piston



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Fig. Fig. 8: With the new brake pads properly installed, guide the caliper over the pads and onto the support bracket

Rear Disc Brakes

See Figures 9, 10, 11 and 12

Always replace the brake pads in sets, meaning BOTH rear wheels.

  1. Raise the rear of the vehicle and support it safely using jackstands, then 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 the strut using wire or a coat hanger.
  6.  
  7. Remove the brake pads, then remove and discard the old brake pad clips from the caliper support.
  8.  
  9. 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.
  10.  

To install:
  1. Using SA91110NE or an equivalent 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; otherwise, the piston and/or caliper will be damaged.
  2.  
  3. Align the piston slots so the slots run perpendicular to a line drawn through the center of the pin holes in the support, as shown in the illustration.
  4.  
  5. Carefully lift the inner edge of the piston boot by hand to release any trapped air. Do not use a sharp tool or damage the piston boot; otherwise, caliper overhaul will be necessary.
  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 while compressing the pin boots by hand. Lubricate the non-threaded portion of the guide and lock pins using silicone grease, then install the pins and tighten to 27 ft. lbs. (36 Nm).
  12.  
  13. Check the position of the pad clips. If necessary, use a small screwdriver or prybar 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 wheels, 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. 9: Remove the pins, then remove the caliper from the support, being careful not to stretch or damage the brake hose



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Fig. Fig. 10: Remove and discard the old shoes and clips from the caliper support



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Fig. Fig. 11: Use a suitable brake piston driver tool to screw the piston back into the caliper



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Fig. Fig. 12: Once properly threaded, the piston indentation slots will align as shown

INSPECTION



When the pads are removed from the caliper, inspect them for oil or grease contamination, abnormal wear or cracking, and for deterioration or damage due to heat. Check the thickness of the pads; the minimum allowable thickness is approximately 3 / 32 in. (2.4mm).

Most brake pads are equipped with a wear indicator that will make a squealing noise when the pads are worn. This alerts you to the need for brake service before any rotor damage occurs.

 
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