Tools You'll Need:
* Jack and Jack Stands: Absolutely crucial for safety. Never work under a car supported only by a jack.
* Lug Wrench: To remove the wheels.
* Wheel Chocks: Place these behind the rear wheels to prevent the car from rolling.
* Socket Wrench Set: You'll need various sizes, likely including 13mm, 14mm, and possibly others depending on your specific caliper design.
* Ratcheting Wrench: Makes the job much easier.
* C-Clamp or Caliper Compressor Tool: Essential for compressing the caliper piston. A C-clamp can work, but a caliper compressor is safer and easier.
* Penetrating Oil (like PB Blaster): Helps loosen any stuck bolts.
* Wrench to loosen caliper bracket bolts (size will depend on your car)
* New Front Brake Pads: Make sure you get the correct pads for your Sunfire model.
* Gloves: To keep your hands clean.
* Safety Glasses: To protect your eyes from flying debris.
* Torque Wrench (optional but recommended): To tighten bolts to the manufacturer's specifications.
Steps:
1. Safety First: Park on a level surface, engage the parking brake, and use wheel chocks on the rear wheels. Jack up the front of the car and securely place it on jack stands.
2. Remove the Wheels: Use your lug wrench to remove the lug nuts on the wheel you're working on. Carefully remove the wheel and set it aside. Repeat for the other side if replacing both sides.
3. Locate the Caliper: The brake caliper is the assembly that holds the brake pads. It's usually bolted to the suspension knuckle.
4. Remove the Caliper: There are usually two bolts holding the caliper bracket to the knuckle. Spray these bolts with penetrating oil and let it sit for a few minutes. Use a socket wrench to remove these bolts. Carefully support the caliper as you remove the bolts. The caliper is heavy and contains brake fluid, so be gentle and avoid dropping it.
5. Compress the Caliper Piston: This is necessary to create space for the new, thicker brake pads. Using a C-clamp or caliper compressor tool, carefully compress the piston back into the caliper. Be careful not to damage the piston seal or the brake line. It’s often easier to compress the piston slightly while still attached to the bracket.
6. Remove the Old Brake Pads: The old brake pads should now be easily removable. They may be held in place by clips or pins.
7. Install the New Brake Pads: Install the new brake pads, making sure they slide in easily and seat correctly.
8. Reinstall the Caliper: Carefully mount the caliper back onto the bracket and bolt it securely.
9. Reinstall the Wheel: Put the wheel back on and tighten the lug nuts. Don't fully tighten them yet.
10. Lower the Car: Carefully lower the car to the ground using the jack.
11. Tighten Lug Nuts: Tighten the lug nuts using a star pattern.
12. Repeat for the Other Side (if necessary): Repeat steps 2-11 for the other front wheel.
13. Test the Brakes: Before driving, pump the brake pedal several times to ensure the brakes are working properly. Take a short, careful test drive to verify braking performance. If the brakes feel spongy or unusual, you may need to bleed the brakes. This is a more advanced procedure, and you should seek professional help if needed.
Important Notes:
* Bleeding the Brakes: While not always necessary after a pad replacement, it's a good idea to check for spongy brakes and if needed bleed the brakes. This procedure removes air bubbles from the brake lines.
* Brake Fluid: Brake fluid is corrosive. If any spills, clean it up immediately.
* Consult a Repair Manual: A repair manual specific to your 2003 Pontiac Sunfire will provide detailed instructions and diagrams, including torque specifications for the bolts. This is highly recommended.
This guide provides general instructions. Specific details may vary slightly depending on your vehicle's configuration. Always consult a repair manual for your specific model before starting any brake work. If you are unsure about any step, consult a qualified mechanic. Improper brake work can be dangerous.
