Field Remedy: 1448
| Subject: |
Rear axle - Low frequency noise |
| Models: |
Engines: |
Option: |
| Astra-G 1998...2003,Zafira
1999...2003,Astra-G Coupe 2000...2003,Astra-G Cabrio
2000...2003 |
All,All,All,All |
|
| Complaint: |
Noises of rear brakes with or without break
operation |
| Cause: |
Stimulation of the brakesystem |
| Production: |
As of the following breakpoints calipers
with a damper and a modified upper sliding pin have been introduced
in production: Plant Bochum I with VIN W0L0TGF3532044143 and
W0L0TGF7532045121, Plant Eisenach with VIN W0L0TGF4836023821, Plant
Antwerp with VIN W0L0TGF..35043736. Plant Ellesmere Port with VIN
W0L0TGF..38009690, Plant Bertone with VIN W0L0TGF073B001191
(Coupe), Plant Bertone with VIN W0L0TGF673B002531 (Convertible),
Plant Rayong with VIN W0L0TGF753H003256. |
Remedy:
In case of customer complaint replace the parking brake cable guides at the
rear brake calipers by new parking brake cable guides with an addtional mass
damper (only valid for TRW calipers, not valid for Bosch calipers).
Note: Replacing the caliper is not necessary. The cleaning, greasing or
replacing of the brake pads does not improve the problem and is not
permissible.
Working Procedure:
1. Raise up vehicle.
2. Clip out protection clip of parking brake cable by using
suitable tool (picture I).
3. Remove return spring of actuating lever by using suitable
tool (picture II).
4. Loosen fastening screw parking brake cable guide (picture III).
5. Release parking brake cable guide with parking brake cable
from caliper (picture IV).
6. Pull parking brake cable out of parking brake cable guide.
7. Plug in parking brake cable in parking brake cable guide with
mass damper.
8. Hang in parking brake cable guide with mass damper and parking
brake cable in brake caliper (picture V).
Note:
Take care for correct seat of parking brake cable guide with damper.
9. Install parking brake cable guide with new screw to caliper.
Torque - 10 Nm (picture VI).
10. Install return spring of actuating lever by using suitable tool.
11. Clip in securing clip of parking brake cable.
12. Lower vehicle.
13. Check adjustment of parking brake
- see working procedure "Parking Brake, Adjust", group "H",
Service Instruction Astra-G/Zafira.
Note: If the low frequency noise reoccurs even though the additional mass
dampers are installed, please implement Field Remedy 1550.
General Note:
1. With introduction of TRW / Lucas caliper an adhesive film on the backside
of the brake pads is used. It is very important that this adhesive film
is not greased or damaged (i.e removing and installing the brake pads).
A damaged or greased adhesive film is ineffective and can cause brake
noise.
2. Before installing new brake pads it is very important to clean the contact
surface of the caliper - especially piston and fingers - from old adhesive
film material. The protection paper on the adhesive film has to be pulled
off after installing the brake pads into the braket but before assembling
the caliper to the bracket.
3. Vehicles before MY 02 which are equipped with Bosch calipers and which are
to be retrofitted with the TRW/LUCAS calipers, require a new handbrake
cable and a mass damper has to be installed.
Spare-Parts: Part-No.: Catalog-No.:
Parking brake cable guide 93 175 246 16 05 074
with damper, left side
Parking brake cable guide 93 175 247 16 05 075
with damper, right side
Labour Times: TC: Hours:
T 8 144 80 Mass damper installation 90 0,4
left + right
The costs for this repair will be covered for vehicles not older than
3 years and a mileage lower than 100.000 Km.
The regular warranty procedure should be used for claiming Set-up-time.
| FunctionalGroup: |
H - Brakes |
| Complaint Group: |
14 - Noises or Vibrations |
| Trouble Code: |
None |
|
