Tools You'll Need:
* Jack and Jack Stands: Essential for safely lifting the car.
* Wheel Chocks: To prevent the car from rolling.
* Lug Wrench: To remove the wheel.
* Sockets and Wrenches: You'll need the correct size for your caliper bolts, and potentially a wrench for the caliper piston.
* Hammer and Punch (or a slide hammer): For potentially persuading the rotor loose.
* Penetrating Oil (like PB Blaster): To help loosen rust and corrosion.
* C-clamp (optional but helpful): Can help compress the caliper piston.
* Gloves: To protect your hands.
Steps:
1. Safety First: Park on a level surface, engage the parking brake, and chock the rear wheels. Use jack stands to lift the car securely after jacking it up, supporting the vehicle's frame near the wheel you're working on.
2. Remove the Wheel: Loosen the lug nuts before lifting the car. Once the car is safely supported, remove the lug nuts and take off the wheel.
3. Remove the Caliper:
* Locate the caliper bolts: These usually are on the back of the caliper.
* Apply penetrating oil: Spray generously around the caliper bolts to help loosen them. Let it sit for a few minutes.
* Remove the caliper bolts: Carefully unscrew the bolts and remove the caliper. You might need to gently pry it away from the rotor. Be careful not to damage the brake lines. You might want to hang the caliper using some wire or a bungee cord to keep it out of the way and prevent stretching or damaging the brake lines.
4. Compress the Caliper Piston: Before removing the rotor, you'll likely need to compress the caliper piston to create enough space. You can do this manually with a C-clamp, or use a specialized caliper piston compression tool. Important: Make sure the brake fluid reservoir is not overfilled as you compress the piston. It may overflow if it's full.
5. Remove the Rotor: This is where the rotor might be stuck.
* Inspect for rust and corrosion: If there's significant rust or corrosion between the rotor and the hub, apply more penetrating oil and let it sit.
* Try tapping gently: Use a hammer and a punch (or a blunt object like a soft-faced mallet) to tap gently around the perimeter of the rotor, alternating between the inside and outside edges. This helps break any rust or corrosion bonds. Avoid hitting the rotor directly in one spot; this could damage it.
* Try a slide hammer (if you have one): This tool is designed for pulling stuck parts. Attach the slide hammer to the rotor's center hole and gently pull.
* If all else fails: If the rotor is truly seized, you may need to use more aggressive methods, but be extremely careful to avoid damaging the hub. Consider professional assistance.
6. Clean the Hub: Once the rotor is off, clean the hub mounting surface of any rust, dirt, or debris.
7. Install the New Rotor (if necessary): If you're replacing the rotor, slide the new one onto the hub. It should fit snugly.
8. Reassembly: Reverse the steps above to reinstall the caliper, compress the piston, and attach the wheel. Remember to torque the lug nuts properly.
9. Test the Brakes: After reassembly, gently pump the brake pedal several times to ensure they're working correctly before driving.
Important Considerations:
* Rust and Corrosion: On an older car like a 1997 Saturn SL1, rust and corrosion are common culprits for stuck rotors. Be prepared to use penetrating oil liberally and allow ample time for it to work.
* Professional Help: If you're uncomfortable performing any of these steps, it's always best to consult a qualified mechanic. Damaging the brake system can be dangerous.
* Brake Fluid: Be mindful of brake fluid. It's corrosive and harmful to your skin and paint. Clean up any spills immediately.
Remember to always consult your vehicle's repair manual for specific torque specifications and other details. This guide provides general advice; your specific situation may require slight variations.
