I wanted to replace the front and rear rotors & pads on my 2004 9-5 Aero coupe. The dealership wanted close to $1000. I purchased KT5783811 from thesaabsite.com, some stuff from AutoZone, and a special tool from NAPA and did the job myself. Take your time and make sure that everything is clean at all times. Here are the highlights:
Front Pad & Rotor Replacement 1. Break lug nuts with 17mm socket (or tire iron from trunk).
2. Withdraw brake fluid from master cylinder to MIN level. Leave cap on loose.
3. Chock front tires. Use two rear jack locations to lift vehicle & support with jack-stand(s) at rear towing eyelet receiver.
4. Remove lug nuts & wheels.
5. Compress one caliper with C-clamp.
6. Remove the two caliper bolts with T-45 socket. Remove the brake pads & suspend the caliper with wire to prevent damage to brake hose.
7. Remove the caliper retaining bracket with 18mm socket.
8. Remove the rotor retaining screw with T-30 socket. Withdraw rotor (using a sledge and/or chemical penetrant if necessary).
9. Install the new rotor insuring that all holes align. Set rotor retaining screw to 10ft-lb.
10. Install the caliper retainer. Add blue Loctite to threads and torque to 155ft-lb.
11. Install the new pads to caliper assembly. Lubricate caliper sliders with PTFE. Apply anti-squeal to all pads.
12. Tighten the caliper bolts to 70ft-lb. Note that you may need a special tool/be creative due to spring interference.
13. Check master cylinder fluid is at MIN. If not, withdraw fluid.
14. Repeat other side.
15. Start vehicle and depress brake pedal multiple times to seat. Add DOT4 brake fluid as necessary.
16. Adjust parking brake pads.
17. Install wheels and hand-tighten. Lower vehicle to ground.
18. Torque lug nuts to 81ft-lb in a star pattern.
19. Start vehicle and depress brake pedal multiple times. Safely road test vehicle.
Rear Pad & Rotor Replacement 1. Break lug nuts with 17mm socket (or tire iron from trunk).
2. Withdraw brake fluid from master cylinder to MIN level. Leave cap on loose.
3. Chock front tires. Use two rear jack locations to lift vehicle & support with jackstand(s) at rear towing eyelet receiver.
4. Remove lug nuts & wheels.
5. Compress one caliper with C-clamp.
6. Remove the two caliper bolts with T-45 socket. Remove the brake pads & suspend the caliper with wire to prevent damage to brake hose.
7. Remove the caliper retaining bracket with 18mm socket.
8. Remove the rotor retaining screw with T-30 socket. Withdraw rotor (using a sledge and/or chemical penetrant if necessary). 9. Install the new rotor insuring that all holes align. Set rotor retaining screw to 10lbf.
10. Install the caliper retainer. Add blue Loctite to threads and torque to 155lbf.
11. Install the new pads to caliper assembly. Insure to lubricate all friction surfaces (pins, back & pad arms. clips, etc.) with PTFE.
12. Tighten the caliper bolts to 70lbf. Note that you may need a special Torx tool and or rotate springs due to interference.
13. Check master cylinder fluid is at MIN. If not, withdraw fluid.
14. Repeat other side.
15. Start vehicle and depress brake pedal multiple times to seat. Add DOT4 brake fluid as necessary.
16. Adjust parking brake pads [I do not have this information].
17. Install wheels and hand-tighten. Lower vehicle to ground and add DOT4 brake fluid as necessary
18. Torque lug nuts to 81lbf in a star pattern.
19. Start vehicle and depress brake pedal multiple times. Add DOT4 brake fluid as necessary and safely road test vehicle. Once I can figure out how to adjust the rear brake pads, I will update. Thanks!
NOTE: These are great instructions.....but let me add a couple of items. On my 2004 9-5 Aero I needed an E-18 inverse Torx socket to remove the front caliper mounting bracket (this may be the "special tool from NAPA" mentioned) I bought one at NAPA for less than $6.00.
If you can secure a T-45 Torx wrench that can be removed from it's socket and turned with an open-end wrench it makes removal and install of rear calipers easier.
Pricing for BRAKE PADS FRONT (brakes & related)
Pricing for BRAKE PADS REAR (brakes & related)
Pricing for BRAKE ROTORS STANDARD (brakes & related)
