SPS

Please take a few minutes and read through these instructions in their entirety BEFORE you start to modify your Saturn. Remember: careful planning and preparation will make your install experience educational and painless.

Rear Hub Spacer Kit Preparation

1. Make sure that you have all the parts listed below before you attempt this installation! Contact SPS immediately if you have questions or concerns regarding part quantities or part descriptions.

Vehicle Preparation and Support

1. Raise the back end of the vehicle and place on jackstands. Be sure that the car is firmly supported before going ANY further with this installation! Note that the car should be in gear and the front wheels should be blocked to keep the car from moving while being supported.
2. Be sure to fully release the vehicle hand brake lever.
3. Remove any rear hubcaps, wheel covers, and both rear road wheels using a 19mm socket.

Rear Caliper and Rotor Removal (Left and Right)

1. Remove the two caliper lock pins from the caliper body mounting ears using a 14mm socket. Be careful not to place the pins where dirt or other contaminants could become stuck to the grease found on the pin body.
2. Pull the caliper body off of the brake pad/caliper support bracket assembly and set it ‘out of the way’. Note: you do NOT need to remove either the parking brake cable or the flexible brake hose from the caliper at ANY time during this procedure!
3. Remove the brake pads from the caliper support bracket. Label the brake pads so that they may be returned to their original location (left inner, left outer, right inner, right outer) during re-assembly.
4. Remove the caliper support bracket from the knuckle using a 10mm socket. Note: these fasteners are found on the back side of the knuckle and are not visible from the front. Leave the caliper pad springs in the caliper support bracket after removal.
5. Remove the rear brake rotor by pulling it toward you. (If the rotor is "frozen" in place, place a small chunk of wood against the rear side of the rotor and tap it gently with a hammer. Then spin the rotor, and repeat this procedure on the opposite side.)
6. If you car is equipped with ABS, disconnect the ABS wheel speed sensor connector found on the back side of the wheel bearing (found directly beneath the wheel cylinder-to-flexible brake hose joint). Carefully move the sensor connector and wire ‘out of the way’ until they are reconnected later in this procedure.

Rear Bearing Removal (Left and Right)

1. Loosen and remove the four fasteners that hold the wheel bearing to the suspension knuckle with a 10mm socket and long extension. You will need to spin the bearing flange occasionally to line up the access holes in the bearing flange with the heads of the fasteners.
2. Remove the bearing assembly by pulling it toward you. In some cases, the bearing may be ‘stuck’ in place. Resist the temptation of beating it free, since the bearing MUST be re-used during re-assembly. Careful use of penetrating oils and mild prying will save you from the expense of buying a new wheel bearing!

Rear Bearing and Spacer Installation (Left and Right)

1. Clean the bearing mounting face and/or the knuckle mounting surface with a Scotchbrite pad to remove any corrosion or crud which may be present. Position the 5mm hub spacer adapter on the mounting face of the rear wheel bearing assembly.
2. Install the original rear wheel bearing to the knuckle re-using the original four 10mm fasteners, capturing the 5mm hub spacer adapter between the knuckle and bearing. Torque the four fasteners in a crisscross sequence to 85 Nm (63 ft-lb). It is recommended that a small amount of Loctite be applied to each of the fasteners prior to re-assembly.
3. If applicable, reconnect the ABS wheel speed sensor to the bearing side connector. Do NOT force this connector if it is difficult to install.

Rear Brake Installation (Left and Right)

1. Clean the face of the bearing flange with a Scotchbrite pad to remove any corrosion or crud which may be present. This step will help to ensure that the rotor is seated on a clean, flat surface.
2. Slide the rotor over the wheel studs and on to the bearing, seating it against the flange. The raised section of the rotor (the ‘hat’ section) should be close to you with the friction surface farther away (inboard). Using a road wheel lug nut, finger-tighten the rotor against the flange to keep it in place for the duration of the re-assembly.
3. Locate the two caliper mounting tabs on the back side of the knuckle (they will be hidden behind the rotor). Slide each of the two 10mm fasteners through the tabs, through one 5mm caliper spacer adapter, and finger-start the fasteners into the caliper support bracket, capturing the 5mm caliper spacer adapter between the knuckle and support bracket. Secure the caliper support bracket by torquing the two 10mm fasteners to 85 Nm (63 ft-lb), making sure that the rotor spins freely between the inboard and outboard sides of the bracket after assembly. Again, it recommended that a small amount of Loctite be applied to the threads before assembly.
4. Re-install the rear disc brake pads into the caliper pad springs in their original positions.
5. Place the caliper assembly over the brake pads and caliper support bracket assembly. Note that before installation, be sure to check that the orientation of the recessed ‘V’ grooves in the face of the caliper piston line up with the anti-rotation pins sticking out of the back side of the brake pad backing plates.
6. Lightly coat the sliding (flat) surfaces (not the threads!) of the caliper mounting pins with silicone grease and install through the caliper body ears and into the caliper support bracket pin boots. Note: the larger diameter pin goes on the ‘bottom’, the smaller pin on the ‘top’. Torque the pins to 36 Nm (27 ft-lb) using a 14mm socket. Do NOT use Loctite on these fasteners!

Vehicle Wrap-Up and Road Test

1. Remove the finger-started lug nuts holding the rear rotors and re-install the rear road wheels. Torque the lug nuts to 140 Nm (103 ft-lb) using a 19mm socket. Note: you will need a buddy to hold the brake pedal down as you torque the lug nuts! Re-install any rear hubcaps or wheel covers also using a 19mm socket.
2. Raise the back end of the vehicle and remove jackstands. Unblock front wheels.
3. With the vehicle on level ground and with the car NOT running, apply and release the brake pedal several times until all clearances are taken up in the system.
4. With the vehicle on level ground and with the car NOT running, apply and release the hand brake lever several times until all clearances are taken up in the system.
5. Road test the vehicle to confirm proper function of both the road brakes and the park brake system. USE CAUTION THE FIRST TIME YOU DRIVE YOUR CAR AFTER MODIFICATION TO ENSURE THE PROPER FUNCTION OF ALL VEHICLE SYSTEMS!
6. Enjoy your modified Saturn!