The Saturn Ion was manufactured by GM Motors from Two thousand three completed 2007. It replaced the S-series Saturns, and was eventually replaced by the Saturn Astra. The Ion was available as a four-door sedan or a two-door coupe. It further features two contrastive types of rear braking systems. While the rear CD brake were fitting also typical, the Ion was yet available with rear drum brakes very.
Instructions
Rear Brake Pads
1. Suspend the rear axle on a lift or jack stands and then remove the rear wheels.
2. Remove the two caliper bolts using a share wrench and allot them aside. Applicability a pry stuff to remove the caliper from the rotor, growth careful not to pinch the caliper bolt boots and malicious them. Suspend the caliper to the chassis with mechanics wire so it does not hang from the brake hose.
3. Application the caliper piston Chauffeur stuff or spanner wrench to turn the piston clockwise into the caliper Muzzle. Arrange not employ a C-clamp or channel locks. The rear calipers on the Ion posses a screw-in Muzzle. Good buy the suitable adapter for the Chauffeur part or spanner wrench and turn the shaft of the belongings with a ratchet and a socket until the slots of the piston are perpendicular to the replacement pads. Lift the border of the rubber piston boot to Proceeds any trapped air and assure it collapses back into abode below the piston face.
4. Remove the debilitated pads from the caliper support. Remove the old pad clips from the support and clean them with a small wire brush and denatured alcohol. Clean the surface of the caliper support in the same manner. Spread a light layer of brake silicone lube to the caliper support beneath the clips. Replace the clips and then apply another layer of lube on the clips where the pad tabs sit. Install the new pads making sure the wear sensor indicator is on the outboard pad.
5. Make sure the piston slots are aligned properly to accept the pads.
6. Remove the mechanics wire from the caliper and place it over the pads and rotors.
7. Place a coating of brake lube on the non-threaded section of the caliper bolts and insert them into the caliper. Torque the bolts to Twenty seven foot-pounds with a torque wrench.
8. Pump the foot brake several times to seat the pads to the rotors after the Ion has been lowered to the ground.
Rear Brake Shoes
10. Lift the Ion and remove the rear wheels.Replace the wheel and torque the wheel nuts to Ninety foot-pounds. Repeat the procedure for the other side.9.
Remove the rear drums. Leave one side of the rear brakes intact at a time to reference their position. This will help after removing the shoes and then putting them back together.
11. Disengage the upper return spring from the rear parking brake shoe and then set it aside. Remove the hold-down spring and pin from the parking brake shoe as you did to the forward shoe in Step 3. Push the lever of the parking brake shoe into the cable spring to disengage the cable from the end lever and then remove the parking brake shoe along with the lever and cable spring. Spread the retaining clip of parking brake shoe with a straightedge screwdriver carefully and then remove the clip and the wave washer.
Press the head of the holding pin of the forward shoe using a finger. It is located on the backside of the backing plate. Use the brake shoe spring tool to compress the spring and then turn the cup to align with the slot of the holding pin. Decompress the spring to remove the spring, cup and holding pin.
13. Remove the adjuster star-wheel assembly by pulling the forward shoe towards the front of the Ion. If necessary, turn the star-wheel to shorten the adjuster length. Reposition the forward show towards the rear of the Ion and release tension on the upper return spring. Slightly twist the shoe to separate it from the spring.
14. Remove the lower return and adjuster springs using a pair of brake shoe pliers. Be careful not to damage them by over-extension if you plan to reuse them.12.
15. Disassemble the brake adjuster socket, screw and nut, then clean the components in denatured alcohol. Inspect the assembly, making sure the screw threads smoothly into the adjusting nut over the full threaded length.
16. Disassemble the brake adjuster assembly and clean them with denatured alcohol and a small wire brush. Apply a liberal coating of silicone brake lube to the treads and reassemble.
17.Clean the six shoe contact points on the backing plate with a piece of emery cloth and then lubricate the points with the silicone brake lube.
18. Reverse the procedure to reassembly the rear brakes, referring to the other side if necessary. Do not replace the drum onto the side you complete first so you can refer to it for the other side to reassemble.
19. Turn the star-wheel adjusters enough to allow the drums to fit snugly after both sides have been reassembled. Turn the drums on the hubs to ensure they do not travel one full revolution when spinning. If they do, turn the star-wheel adjuster out more and try it again.
20. Replace the rear wheels and wheel nuts and torque the nuts to Ninety foot-pounds with a torque wrench.
