Subject:
Rear wheel disc brake.
Vehicles:
All Astra-G and Zafira models with rear wheel disc brake.
Condition:
1) Locking of rear wheels after releasing the parking brake.
No parking brake operation. Considerable wear of the brake linings on the rear
wheel disc brake.
2) Modified parking brake cables
Cause:
Re 1: Insufficient lubrication of the inner parts for parking
brake actuation in the brake calliper of the rear wheel disc brake.
Re 2: Damper on the brackets for the parking brake cable on
the brake calliper of the rear wheel disc brake discontinued. Implementation of
a new, modified parking brake cable with integrated damper.
Remedy for 1):
Replacement of both rear brake callipers.
In the new brake callipers available from Aftersales, the
seals have been modified on the parking brake lever and the interior parts have
been packed with sufficient grease.
In addition, the new brake callipers are supplied with
modified brackets for the new parking brake cables.
As a result, the procedure for replacement of the rear brake
callipers has been modified, as described below:
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Brake Calliper - Rear Wheel Brake, Replace
Remove, Disconnect
Release parking brake lever. Detach folding cover for
parking brake lever. Release parking brake cable by turning back the
adjustment nut. Fill brake fluid reservoir to "MAX" mark and seal
with MKM-558-10.
Remove rear wheels.
Press actuation lever downwards with screwdriver and detach
parking brake cable (1). Detach retaining clip and pull parking brake cable
from bracket.
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Remove, Disconnect
For vehicles with damping weight on brake calliper: Detach
spring (4) and remove fastening bolt for parking brake cable bracket (5) from
brake calliper. Remove parking brake cable bracket (2) with damping weight.
Detach brake hose (6) from brake calliper - collect
escaping brake fluid and close off opening.
Remove fastening bolt (3) with metal guide sheet for brake
calliper.
Swing brake calliper upwards and remove brake linings from
brake carrier.
Remove fastening bolts for brake carrier (1) from brake
carrier plate and remove brake calliper with brake carrier.
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Install, Attach
Attach brake carrier for new brake callipers to brake
carrier plate - re-cut threads and insert fastening bolts (1) with
locking compound, Catalogue No.: 15 10 181, Part No.: 90 542 117 -
tightening torque 100 Nm/74 lbf. ft.
Remove fastening bolt (2) with metal guide sheet and swing
brake calliper upwards.
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Install, Attach
Coat brake carrier (1) in the mounting area of the brake
linings (arrows and shaded areas) with anti-squeak compound, Catalogue No.:
19 42 586, Part No.: 90 166 282 (illustration shows this area with the brake
calliper removed for clearer representation).
Insert new brake linings in brake carrier - brake
lining and wear indicator must be seated on the inside. Swing brake calliper
downwards. Re-cut thread and insert fastening bolt with locking compound.
Install fastening bolt with metal guide sheet - tightening torque 25
Nm/18.5 lbf. ft.
For vehicles with damping weight on brake calliper: Remove
spring. Detach parking brake cable from new brake calliper. Attach old
bracket for parking brake cable (4) with damping weight to new brake
calliper - re-cut thread and insert fastening bolt with locking
compound - tightening torque 11 Nm/8 lbf. ft. Attach spring to parking
brake cable bracket and parking brake lever.
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Attach brake hose (2) to brake calliper with new seal
rings - tightening torque 40 Nm/29.5 lbf. ft. Mount rear wheels -
tightening torque 110 Nm/81 lbf. ft.
Bleed brake system and check for leaks - see operation
"Brake System, Bleed and Check for Leaks" in group "H" of
the Service Instructions for Astra-G or Zafira.
Actuate brake pedal at least 5 times. Top up brake fluid to
"MAX" marking.
Attach parking brake cable (3) to bracket with new
retaining clip. Press actuation lever downwards with screwdriver and attach
parking brake cable. Adjust parking brake - see corresponding operation.
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Remedy for 2):
As of approx. mid-April '99, the damper on the bracket for
the parking brake cable is no longer in production, as it has been integrated
into the parking brake cable.
When replacing the parking brake cable with the new
version, the damper attached to the brake calliper must be removed. As a
result, the operation has been modified as follows:
Parking Brake Cable, Replace (Vehicles with Rear Wheel
Disc Brake)
Remove, Disconnect
Remove centre console cover. Unclip folding cover for
parking brake lever from centre console and pull up to handle.
Slacken parking brake cable on the parking brake lever by
turning back the adjustment nut.
Press actuation lever for brake calliper downwards with
screwdriver and detach parking brake cable. Detach retaining clip from
parking brake cable and remove parking brake cable from bracket.
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Disconnect wiring harness plug for oxygen sensor and
release wiring harness from fastenings. Detach front exhaust pipe (1) and
centre muffler (2). Detach rubber exhaust mounts (4) for centre muffler from
vehicle underbody.
Detach heat shield for centre muffler (3) from vehicle
underbody.
Push back protective sleeve for front parking brake cable
(5). Turn front parking brake cable (6) by 90° and detach from parking brake
cable compensation yoke.
Detach parking brake cable from brackets on rear axle, rear
axle bracket and fuel reservoir (7).
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Remove, Disconnect
For vehicles with damping weight on brake calliper and for
replacement of the parking brake cable: Detach fastening nut for damping
weight on brake calliper from bracket and remove damping weight and retaining
cable from bracket.
Install, Attach
Attach parking brake cable to brackets (1) on rear axle,
rear axle bracket and fuel reservoir (7).
Attach front parking brake cable (2) to parking brake cable
compensation yoke and turn 90° - ensure that the T-piece at the end of
the front parking brake cable is correctly seated in parking brake
compensation yoke (arrow). Push the protective sleeve for the front parking
brake cable (4) towards the parking brake compensation yoke until over the
bead (3) on the parking brake cable in order to prevent the protective sleeve
from shifting and the parking brake compensation yoke from coming loose.
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Insert parking brake cable in bracket and attach new
retaining clip to parking brake cable. Press actuation lever for brake calliper
downwards with screwdriver and attach parking brake cable to brake calliper
actuation lever.
Attach heat shield for centre muffler (7) to vehicle
underbody - tightening torque 2 Nm/1.5 lbf. ft. Attach rubber exhaust
mounts for centre muffler (8) to vehicle underbody.
Attach front exhaust pipe (5) and centre muffler (6). Route
wiring harness for oxygen sensor and connect wiring harness plug.
Adjust parking brake - see corresponding operation.
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Parking Brake, Adjust
Remove centre console cover.
Unclip folding cover for parking brake lever (2) from
centre console and pull upwards.
Adjustment nut (3) must be fully turned back. Set parking
brake lever (1) to position "0" (released).
Depress brake pedal at least 5 times to adjust the parking
brake play on the brake calliper - ensure that the brake pedal fully
returns to its original position (pedal released) after each actuation.
Pull parking brake lever to stop 5 times and release. Pull
parking brake lever (1) to third notch and turn adjustment nut on parking
brake lever (3) until the rear wheels are difficult to turn.
The braking effect must be equal on both wheels.
Clip folding cover for parking brake lever onto centre
console. Attach centre console cover.
Note:
The modifications to the relevant operations will be
incorporated in the next edition of the corresponding Service Instructions
and Labour Time Guide.
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Parts:
The catalogue numbers and part numbers necessary for the
modifications can be found in the Parts Catalogue.
Time Allowance:
Op. no. Description hrs
H 1270 00 Brake Calliper, Replace - Both
Rear Sides 1.2
TC: 01, 05, 12, 15, 42
+: Replace brake pads, bleed
brake system and
check for leaks (Brake Pedal
Tensioner KM - 325),
re-cut threads, adjust parking
brake lever travel, lubricate brake carrier
-: Replace brake carrier
H 3213 00 Centre Parking Brake Cable, Replace 1.2
TC: 01, 06, 15
+: Adjust parking brake lever
travel, R + R heat shield,
R + R exhaust, detach damping
weight from brackets
The specified time allowances do not include the time
allowance for the vehicle set-up of .2 hrs.
For reimbursement of the vehicle set-up time of .2 hrs in
warranty claims, enter the authorisation code "T" and increase the
main operation time allowance by .2 hrs.
The authorisation code may be used once per work order. It
may only be used more than once if the workplace and workteam are changed at
the same time.
