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Home >> Saturn >> 2003 >> Ion 1 Standard >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Disc Brakes & Drum Brakes >> Removal & Installation >> Front Brake Caliper >> Removal

Front Brake Caliper: Removal

  1. Inspect brake fluid level in master cylinder reservoir.
  2. If brake fluid level is midway between the maximum and minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
  3. If brake fluid level is higher than midway between the maximum-full point and minimum allowable level, remove brake fluid to midway point before proceeding.
  4. Raise and support vehicle.
  5. Remove tire and wheel assembly.
  6. Install and firmly hand tighten 2 wheel lug nuts to opposite wheel studs to retain rotor to hub.
  7. Install a large "C" clamp over the body of the brake caliper with the "C" clamp ends against the rear of caliper body and against the outer brake pad. See Figure.
  8. Tighten "C" clamp until caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.
  9. Remove "C" clamp from caliper.
  10. Remove brake hose-to-caliper bolt from brake caliper.
  11. Remove brake hose from brake caliper.
  12. Remove and discard 2 copper brake hose gaskets. Gaskets may be stuck to brake caliper and/or brake hose end.
  13. Cap or plug the opening in the brake caliper and brake hose to prevent fluid loss and contamination.
  14. Remove brake caliper guide pin bolts.
  15. Remove brake caliper from caliper bracket.
  16. Inspect brake caliper guide pins for freedom of movement. Inspect condition of guide pin boots.
  17. Move guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for restricted caliper guide pin movement, looseness in brake caliper mounting bracket, seized or binding caliper guide pins, or for split or torn boots. Repair or replace as necessary.
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