I have a 2007 2.4 hhr and I'm replacing the original rotors and pads on the front. I took apart the passenger side brakes to find out JCWhitney sent me the wrong size rotor so I put the old pads and rotor back on.

This is when I noticed that one of the old pads was hardly worn and the other was down to the wear bar???? Unfortunately I didn't pay attention to which pad was outer and which was inner. Has anyone else had this issue????

What upsets me is that I was at the dealer a week earlier for tires and I complained as I do everytime I am at the dealer about the brakes being utter crap and the car shuddering violently when I brake. So I have them check the front brakes while they have the tires off and they say the brakes look fine other than the pads need change and they would sell me a $150 pair of rotors that would help make it brake smoother. They showed me One of the brake pads and it is worn all the way down so I told them that I would do the brakes myself because I want to live and Chevy has never shown any interest in fixing this obvious defect in their vehicle and I find it insulting that they want to make money off their incompetence.

So, the dealer seemed fine with the fact that only one of the brake pads was doing the braking (idiots) and I have no Idea if the put the pads back in the original positions or swapped them. I haven't touched the driver side yet and am running to the store for brake cleaner and then will finish the brake job.

So my questions are: Is this a known issue? What should I look for when pulling apart the drivers side (will check for piston marks on both pads to see if they swapped locations) but is there anything else I should look for?

I am no brake expert at all but have worked on equipment and cars enough that I don't trust most shops to do a better job than I can do with a little research so has anyone already been through this?

 

Interesting, 5 sec. google got me this:

2008 Chevrolet Cobalt | Cobalt, G5 (VIN A) Service Manual | Brakes | View All Bulletins | Document ID: 2170217
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#08-05-23-003B: Front Brake Noise, Brake Pulsation, Front Brake Inner Pad Wear (Replace Front Brake Pads and Add Splash Shields) - (Jul 21, 2008)


Subject: Front Brake Noise, Brake Pulsation, Front Brake Inner Pad Wear (Replace Front Brake Pads and Add Splash Shields)


Models: 2005-2008 Chevrolet Cobalt (Excludes SS Models)

2006-2008 Chevrolet HHR (Excludes SS Models)

2006 Pontiac Pursuit (Canada Only)

2007-2008 Pontiac G5




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This bulletin is being revised to clarify the vehicles involved in the model and parts information. Please discard Corporate Bulletin Number 08-05-23-003A (Section 05 -- Brakes).


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Condition
Some customers may comment on a brake noise and/or pulsation on brake apply. This condition can be more frequent if the customer resides or travels on dirt/gravel roads and usually occurs within 11,300 km (7,000 mi) to 16,000 km (10,000 mi) intervals.

Upon investigation, the technician may find that there is considerable difference between the front brake outer and inner pad thickness.

Cause
This condition may be due dust, dirt, and debris intruding between the inner brake pad and rotor.

Correction
Road test the vehicle and confirm that the brake noise and/or pulsation is coming from the front brakes. If it is determined that the noise is coming from the front brakes and there is a measurable difference between the outer and inner pad thickness, remove the front wheel bearing/hub assembly following published SI procedures, remove the bearing/hub-to-steering knuckle ****er and replace the ****er with a splash shield on each side.

Replace the front brake pads and follow the procedures outlined in Service Bulletin 00-05-22-002J for servicing the disc brake rotors.

Parts Information
Part Number
Description
Model
Usage

25884778
Shield, Front Brake (RH)
HHR

(EXC SS)
All

(EXC JL9)

Cobalt/G5/Pursuit

(EXC Cobalt SS)
w/ JL9 (level 3) (296 mm rotor)

(EXC JL4)

25884779
Shield, Front Brake (LH)
HHR

(EXC SS)
All

(EXC JL9)

Cobalt/G5/Pursuit

(EXC Cobalt SS)
w/ JL9 (level 3) (296 mm rotor)

(EXC JL4)

25931624
Shield, Front Brake (RH)
Cobalt/G5/Pursuit

(EXC Cobalt SS)
w/ J41 or

JM4 & PFD/PG1 or

JM4 & NZ0/NZ6

(level 0, 1 & 2) 256 and 280 mm rotors)

25931625
Shield, Front Brake (LH)


Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

H9730*
Replace Front Brake Pads and Add Splash Shields (Inc Refinish Rotors)
2.2 hrs

*This labor operation number is for bulletin use only. This number will not be published in the Labor Time Guide.

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.

WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION


© 2009 General Motors Corporation. All rights reserved.
This is taken directly from the GM service website.

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Time for me to take a couple brake pads and the tsb up to the dealer and let them know I'm not impressed.

 

On my HHR the outer pads were worn almost to the metal, the inners still had a lot of meat left. Make sure the caliper can move on it's mounting pins.

 

In theory both pads should wear the same but in the real world it's not uncomon for the pads to wear uneven due to sticky slide pins and inperfections from one side of the rotor to the other. When doing your brakes make sure the slides are free and lube them,replace the rotors and pads and you should be fine.

 

Yeah this is why I usually agree to the dealer doing the recommended brake service when Im in for an oil change. They check for even wear and lube the pins. I like it when things run smooth.

 

Yeah, well my dealer saw no issue with one pad being pretty much new and the other one wore out. Unfortunately I couldn't find anything wrong with the pins or anything else and it did it the same on both sides so I figure it is normal for the way the brakes were engineered on the HHR. So, it really is no wonder that everyone has problems with the brakes on the HHR, they were engineered like crap.

I went through and installed a pair of Napa Ultra Premium Rotors and Raybestos Professional Grade Ceramic Pads and it is braking smooth and quiet.

 

Typically it is the inner pad that wears more, on account of geometry and fluid dynamics. When you un-apply the brakes, theoretically the sealing gasket in the caliper pulls the piston back; sometimes it only releases the pressure, letting the inner pad ride on the rotor.

Anyway, the usual culprit is the 2 cent "square cut" gasket that seals the piston in the cylinder. In my limited experience, most of the times I have experienced outrageously uneven wear it was solved by A) re-lubing the pins, And B) pushing the pistons all the way home when replacing the pads. The "OFFICIAL" remedy is re-build/replace the caliper (that mostly means replacing the gaskets).

The engineering Gods say that that "square cut" gasket really is enough to retract the piston. The theory is the piston mis-shapes the rubber by friction, and then the rubber returns to it's original shape pulling the piston back with it. As the pads wear down the piston incrementally pushes through the gasket.

So, uneven pad wear is a symptom of caliper wear! Don't rule out pins, but that is the less likely cause; more likely leading/trailing edge wear.

Is that a clear thought?