How Do I Fix a 2004 Saturn Ion's Front Brakes?

The Saturn S-Series had a long and relatively successful run as the automakers entry-level vehicle, but its reign came to an end in 2003 when Saturn revealed the all-new Ion Quad Coupe. The 2004 Saturn Ion came standard with a 2.2-liter four-cylinder engine that produced 140 horsepower. Also standard on the Ion were ventilated front disc brakes. Replacing the pads on the front of the Ion is a great way to save some money, but you must always check the condition of the rotor to assure a long pad life.

Instructions

Park the Saturn on a level area and wedge wheel chocks under the rear wheels. Loosen the front lug nuts with a breaker bar and socket, and lift the front of the Ion with a floor jack. Set jack stands under the subframe and lower the vehicle onto the jack stands. Remove the front lug nuts and pull the wheels off of the vehicle.

Position a drain pan under the front caliper and set an 8-inch C-clamp so its fixed end wraps around the caliper and its screw end contacts the rear of the outer brake pad. Loosen the bleeder valve the small, metal valve on the top of the caliper one full turn with a six-point, box-end wrench, then immediately tighten the C-clamp until it stops moving. Immediately close the bleeder valve and remove the C-clamp. This presses the caliper piston back into the caliper.

Remove the two caliper bolts with a ratchet and socket, and lift the caliper from its bracket. Hang the caliper from the front strut spring with a bungee strap, to avoid damaging the caliper hose. Pull the brake pads from the caliper bracket and pry the pad retainers the small shims above and below the pads inside the bracket from the bracket, using a flat-head screwdriver.

Drag your thumbnail across the face of the rotor and feel for grooves deep enough to catch your thumbnail. If the rotor feels smooth, proceed to the section titled Installation.
If there are deep grooves, then remove the two caliper bracket bolts with a breaker bar and socket, and pull the caliper bracket from the front steering knuckle. Pull the rotor off of the front hub; if it is stuck, lightly strike the rotor with a rubber mallet to free it.

Proceed to Step 2 if you are not replacing the brake rotor.
Clean the anti-rust coating and dirt off of the new rotor, if you are replacing it, with brake cleaner and a clean, lint-free cloth. Align the rotor with the front wheel studs and guide the rotor onto the front hub. Install the caliper bracket and tighten its retaining bolts to 85 foot-pounds, using a torque wrench and socket.

Press the new brake pad retainer included with the new pads into place in the caliper bracket. The retainers are hard-formed, so they can only install in one direction. Slide the new brake pads into the caliper bracket, remove the caliper from the bungee strap and lower the caliper onto the its bracket. Tighten the caliper bolts to 27 foot-pounds.

Repeat the removal and installation process on the other side of the Ion.

Reinstall the front wheels and hand-tighten the lug nuts. Raise the vehicle off of the jack stands and remove the stands. Lower the Ion to the ground. Tighten the lug nuts, in a crisscross pattern, to 138 foot-pounds.

Press and release the brake pedal until it feels firm, then check the fluid level in the master cylinder reservoir. If the level is below the Max line, add fresh DOT 3 brake fluid to it to reach this level. Take the old brake fluid to a used automotive fluid recycler or to an auto parts store for disposal.

Drive the Ion to a smooth road of parking lot with little to no traffic. Perform 20 stops from about 25 mph under medium brake pressure dont lock up the brakes with 1-minute pauses between repetitions to burnish the pads and rotors.