Mechanics

BRAKES

2005 Saturn Relay • 6 cylinder AWD Automatic •

How to change brake pads on rear of Saturn Relay
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Cojordet
January 1, 2011.



BRAKE PADS REPLACEMENT - REAR (RPO J65, JL9)

Removal Procedure

1. Inspect the fluid level in the brake master cylinder reservoir.
2. 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.
3. 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.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.
6. Unclamp the wheel speed sensor (WSS) harness from the lower control arm.
Fig. 21: Locating Brake Caliper Bolts
Courtesy of GENERAL MOTORS CORP.
7. Remove both upper and lower caliper bolts (3) from the caliper (1).
Fig. 22: View Of Brake Caliper And Caliper Bracket
Courtesy of GENERAL MOTORS CORP.
8. Pull the caliper (2) straight off of the bracket and secure out of the way with heavy mechanics
wire (1). DO NOT disconnect the hydraulic brake flexible hose from the caliper.
9. Remove the inboard and outboard pads from the brake caliper bracket.
Installation Procedure

? Inspect the brake caliper bracket guide boot assembly for condition. Refer to Disc Brake
Hardware Replacement - Rear.
? Clean the brake pad hardware mating surfaces on the caliper bracket of any debris or corrosion.
? Inspect the brake pad retainer clips for condition and replace, if necessary.
? Inspect the piston boot for condition. Replace if damaged. Refer to Brake Caliper Overhaul -
CAUTION: Refer to Brake Dust Caution in Cautions and Notices.
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.
Rear.
Fig. 23: Rotating Piston In Caliper Body
Courtesy of GENERAL MOTORS CORP.
1. Retract the brake caliper piston (2) into the brake caliper bore. Use a suitable spanner type
wrench and turn the piston clockwise until it bottoms out fully in the brake caliper (MacĀ®
Tools DBC 25 C 2500 MA Disc Brake Caliper Tool Set, or equivalent).
2. Align the indents on the piston face to match the pin on the back of the inboard brake pads.
3. Install the brake pad retainers into the brake caliper bracket.
4. Install the inboard and outboard brake pads into the brake caliper bracket insuring that the pad
with the metallic wear sensor is placed on the inboard side of the bracket.
5. Slide the caliper onto the bracket insuring that the bracket guide boots are not damaged.
6. Insert the brake caliper bolts.
Tighten: Tighten the brake caliper bolts to 34 N.M (25 lb ft).
7. Re-clamp the WSS harness onto the lower control arm.
8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.
9. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel
distance.
11. Slowly release the brake pedal.
12. Wait 15 seconds, then repeat steps 10-11 until a firm brake pedal apply is obtained. This will
properly seat the brake caliper pistons and brake pads.
13. Fill the brake master cylinder reservoir to the proper level. Refer to Master Cylinder
Reservoir Filling in Hydraulic Brakes.
14. Burnish the pads and rotors. Refer to Burnishing Pads and Rotors.
BURNISHING PADS AND ROTORS

Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces
are properly prepared after service has been performed on the disc brake system.
NOTE: Refer to Fastener Notice in Cautions and Notices.
CAUTION: Road test a vehicle under safe conditions and while obeying all
traffic laws. Do not attempt any maneuvers that could jeopardize
vehicle control. Failure to adhere to these precautions could lead
to serious personal injury and vehicle damage.
CAUTION: Refer to Brake Dust Caution in Cautions and Notices.
This procedure should be performed whenever the disc brake rotors have been refinished or replaced,
and/or whenever the disc brake pads have been replaced.
1. Select a smooth road with little or no traffic.
2. Accelerate the vehicle to 48 km/h (30 mph).
3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow
the brakes to lock.
4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient
cooling periods between stops in order to properly burnish the brake pads and rotors.
IMPORTANT: Use care to avoid overheating the brakes while performing this
step.


Merlin2021
Jan 1, 2011.