Troubleshooting Brakes on a Saturn

A power brake boost leak would make it harder for the brakes to be applied in each subsequent use, but I don't think that that would cause a grinding sound. It almost sounds like you have a stuck caliper or piston that is preventing the pads from releasing the disk. As the disk heats up during the drive, fluids can even boil in the hydraulics and bingo insufficient brakes just when you don't want it. A frozen caliper would also explain why you've been getting many miles between brake jobs, the pads just won't wear away.

Do not let this go to long. Brakes are the primary safety system of any vehicle. Get this fixed.

Please! What happens if a little kid runs out in front of you as you go 35MPH and can't stop in time?

Have it towed to a shop.

1 When you say pads are fine, How much braking material is left on them ?

2 Is the break fluid going down in the resovoir ?

3 Can you say where the "Grinding Noise is coming from Front or Back ?

4 When were the brakes replaced last ie how many miles ago.

5 if the brake shoes and pads have not been replaced how many miles has vehicle done.

6 And the last one, Try using the hand brake only on a strech of empty road to slow car down, and see if that produces the noise.

If you hear the grinding noise when using the hand brake only, Your rear shoes or pads have worn down and need replacing.

It is very common on front disc rear drum brakes for the pads only being changed when serviced and the rear shoes not to be replaced as they down wear down as fast as the front brakes, as the rear brakes only contribute about 25% of the total braking force applied by the driver.

please report back findings

How many miles have been driven between the first brake application and 2nd & 3rd?

How did you check the pads? Did you remove the front wheels to check all 4 pads or did you do a fast outside visual check?

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Put on new pads and rotors. This sounds like a comination of new pads on worn down rotors and a serious need to bleed the brakes. You may end up rebuilding the pistons in the calipers. The brake pads wont grind unless the are cracked, worn away or, have trapped foriegn material like oil and dirt from a leaking cylinder. If you aren't capable don't screw with it and go to a brake shop.

I had a similar problem on my '94 saturn. There is a another hydraulic link in the brake system. When you press the brake pedal, it operates a small master cylinder on the firewall, which moves a slave cylinder attached to the main master cylinder. The small system was leaking, causing the mushy pedal response & problems stopping.

The small master-slave pair is a 1-piece system, tubing included, and must be replaced as a unit. It cost me ~$100 in 2004.