2002 Buick LeSabre Rear Brake Pad Replacement Instructions

In 1951, General Motors showed the public a modern marvel of concept cars, the LeSabre. This ultra-modern concept included features that were well ahead of their time, including 12-volt electronics, aluminum and magnesium body panels, fuel injection, built-in hydraulic jacks and a rain-activated automatic convertible top. Unfortunately, this version of the LeSabre was extremely expensive to build -- rumored to be between $500,000 and $1,000,000 -- so it never became a reality. In 1959, Buick snagged up the LeSabre name and released a slightly tamer version of the vehicle, though it still had built-in hydraulic jacks. By time the 2002 model year rolled around, the LeSabre had become a staple in Buick's lineup and was the America's best-selling full-sized car. Replacing the rear brake pads on the 2002 LeSabre requires special care, as you need to deal with the parking brake system.

Instructions

1

Park the LeSabre on a level surface and leave the parking brake disengaged.

2

Unscrew the lid from the master cylinder, and use a clean turkey baster to siphon out about half of the brake fluid. Transfer this siphoned fluid to a small container for later disposal -- do not reuse this fluid.

3

Loosen the rear lug nuts, using a ratchet and socket. Raise the rear of the LeSabre with a floor jack, and slide jack stands under the rear control arms. Lower the LeSabre onto the jack stands. Remove the lug nuts, and pull the rear wheels from the vehicle.

4

Trace the parking brake cable toward the brake caliper until you find where the end of it connects to the parking brake lever on the caliper. Grip the metal end of the parking brake cable with slip-joint pliers, and pull it downward until it's clear from the parking brake lever. Slip the parking brake cable through the slot on the lever, and position the cable aside.

5

Trace the parking brake cable toward the lower control arm until you find the bracket securing the cable to the lower control arm. Remove the bracket bolt with a ratchet and socket, and pull the bracket from the control arm.

6

Remove the two caliper-retaining pins, using a ratchet and socket. Pull the caliper up and off the caliper bracket. If the caliper does not pull off easily, pry upward on it with a 6-inch pry bar until it is free from the bracket. Hang the caliper from a nearby suspension component, using a bungee strap -- never allow the caliper to hang by its rubber hose.

7

Pull the inner and outer brake pads from the caliper bracket. Pull the brake pad clips -- the thin metal shims -- from the top and bottom of the caliper bracket. Remove the two caliper bracket bolts, using a ratchet and socket, and pull the caliper bracket from the rear hub. Pull the rotor from the LeSabre's rear hub; if it sticks to the hub, lightly strike it with a rubber mallet to free it.

8

Inspect the rotor for any visible defects, including deep grooves, mirror-like shine, hot spotting, grinding or cracking. If any defects exist, replace the rotor with a new one. Set the new or old rotor on the LeSabre's rear hub.

9

Apply a thin coat of a thread-locking chemical, and allow the chemical to cure for the time specified by its instructions -- typically 5 to 10 minutes. Set the caliper bracket back onto the rear hub, and hand-tighten the caliper bracket bolts. Apply 94 foot-pounds of torque to the caliper bracket bolts, using a torque wrench and socket.

10

Press new brake pad clips -- included with the new brake pads -- into the caliper bracket; the clips are asymmetrical, so they only fit in one direction. Spin the rotor to make certain the clips do not rub the rotor.

11

Apply a generous coat of disc brake grease -- anti-squeal grease -- to the brake pad clips and the rear of the new brake pads. Slide the new brake pads into the caliper bracket.

12

Wipe the old grease off the brake caliper pins, using a clean, lint-free cloth, and apply a coat of disc brake grease to the smooth part of the caliper pins -- do not get grease on the threads. Remove the bungee strap from the brake caliper, and compress the caliper piston using a rear caliper tool. The exact process varies, depending on the type of tool used, but the concept is to press the piston inward while rotating the piston clockwise until it bottoms out inside the caliper.

13

Turn the caliper piston slightly, using the rear caliper tool, so the grooves in the piston line up with the alignment tabs on the rear of the inner pad. Set the brake caliper on the brake caliper bracket, and install the caliper pins. Apply 20 foot-pounds of torque to the caliper pins, using a torque wrench and socket. Set the brake-hose-to-lower-control-arm bracket back in place on the lower control arm, and tighten its bolt to 18 foot-pounds.

14

Grip the metal end of the parking brake cable with slip-joint pliers, and pull the cable downward until you can slide the cable through the slot in the caliper's parking brake lever. Allow the parking brake cable to retract slowly toward the parking brake lever, until the cable's metal end seats into place in the lever.

15

Repeat Steps 4 through 14 to replace the pads on the opposite side of the LeSabre.

16

Reinstall the rear wheels onto the LeSabre's rear hubs, and hand-tighten the lug nuts. Raise the rear of the vehicle off the jack stands, using a floor jack, and remove the jack stands. Lower the LeSabre to the ground, and tighten the lug nuts -- in a crisscrossing pattern -- to 100 foot-pounds.

17

Press the brake pedal slowly about 2/3 of its total travel, and slowly release it. Repeat this step every 15 seconds until the brake pedal feels firm. This pushes the caliper piston out and seats it on the rear of the inner brake pad. Pushing and releasing at a fast rate may cause the piston to rotate slightly, negatively affecting the alignment of the grooves in the caliper piston to the tabs on the rear of the pad.

18

Add DOT 3 fluid to the master cylinder until the fluid level reaches the "Max" line on the master cylinder reservoir. Tighten the cap onto the master cylinder reservoir.

19

Take the old brake fluid in the small container to a used automotive oil-recycling center for disposal. Some auto parts stores take old DOT 3 fluid free of charge.