Vauxhall Workshop Service and Repair Manuals

REAR AXLE, DAMPING PARTS

Rear Axle, Remove and Install or Replace

Note:

Examples involve operations with drum brakes.

Only where there are deviations in operations involving disc brakes will these be specially described.

Remove

All Models except 38 and 48 (Combo/Astramax)

Unscrew cover from brake fluid reservoir and close off with blind screw cap (commercially available).

Raise vehicle and remove rear wheels.

Mark rear wheel position.

On vehicles with car level control, relieve air pressure.

On Models with Drum Brakes

Measure length of thread on parking brake lever push rod.

Unscrew self-locking nut from push rod.

Remove lock plate (arrow) from brake cable compensation yoke.

Detach parking brake cable from brake cable compensation yoke.

Detach parking brake cable from guides on transmission tunnel and plastic sleeves from hook on fuel tank and place towards exhaust muffler.

On Models 35, 36, 45 and 46, remove parking brake cable from mounting on vehicle underbody.

Detach exhaust muffler from vehicle underbody.

On Models with Disc Brakes

Detach return spring "B" and parking brake cable "A" at brake cable lever.

Press parking brake retaining clamp out of brake cable guide bracket with a screwdriver.

Remove parking brake cable from bracket on rear axle.

Unscrew brake lines from brake pressure hoses at rear axle bracket and remove lock plates.

Remove brake pressure hoses from bracket.

On Models 35, 36, 45 and 46, unbolt bracket for spring of brake proportioning valve from axle assembly.

Place hydraulic jack with special mount (workshop-manufactured) under one rear axle arm and raise slightly.

The special mount is to be manufactured as an assembly aid in the workshop according to the adjacent diagram.

Note that dimension A is that of the vehicle jack or hydraulic jack being used.

Remove shock absorbers.

On all Models except 35, 36, 45 and 46, remove fastening bolt from rear axle arm.

On Models 35, 36, 45 and 46, unscrew hex cap nut from shock absorber and remove washer and rubber parts.

Lever shock absorber out of bracket on rear axle arm using mounting iron if required.

Not required on Models 35, 36, 45 and 46.

Lower hydraulic jack.

Remove rear spring.

If required, press rear axle arm downwards using mounting iron placed in shock absorber bracket and remove rear spring.

Remove shock absorber and rear spring on other side of vehicle following same sequence.

On Models 35, 36, 45 and 46, remove rear springs according to description in "Rear Springs, Remove and Install or Replace".

Place hydraulic jack centrally under rear axle.

Unbolt rear axle mounting from vehicle underbody and remove.

Lower rear axle with hydraulic jack. Place parking brake cable over exhaust muffler.

On Models 38, 48 (Combo/Astramax)

Unscrew cover from brake fluid reservoir and close off with blind screw cap - commercially available.

Raise vehicle and remove rear wheels.

Mark rear wheel position.

Remove both brake drums.

If required, relieve tension on brake shoes using a screwdriver through aperture.

Press parking brake shoe lever forwards - in direction of travel - and disconnect parking brake cable.

Press spring of parking brake cable together, remove plastic sleeve from brake anchor plate and from parking brake cable.

Unscrew brake lines from brake pressure hoses at rear axle bracket and remove lock plates.

Remove brake pressure hoses from bracket.

Important: Note different union screws.

Place hydraulic jack centrally under rear axle.

Remove fastening bolts for both shock absorbers.

Unscrew fastening nut for washer of auxiliary spring.

Remove washer.

Unscrew fastening nuts for U-bracket.

Remove U-bracket and tensioning plate from rear axle or rear spring.

Important:

Rear axle will rotate on hydraulic jack.

Lower rear axle on hydraulic jack.

Remove rear axle from hydraulic jack (two mechanics) and clamp in vice with protective jaws.

Rear Axle, Convert - all Models except 38, 48 (Combo/Astramax)

Remove rear axle from hydraulic jack (two mechanics) and clamp in vice with protective jaws.

Further operations required when replacing a rear axle are described below.

On Models with Disc Brakes

Press brake line out of bracket.

Unscrew brake caliper and remove along with brake line.

Unscrew brake line bracket and attach to new axle.

Lever off dust cap.

Remove split pin from wheel spindle nut and unscrew from wheel spindle.

Remove disc hub from wheel spindle.

Note:

If the disc hub cannot be removed, loosen the parking brake shoe adjustment screw.

See corresponding operation in group H.

Loosen and remove wheel spindle retaining bolts.

Note:

Always use new retaining bolts.

Remove wheel spindle with parking brake carrier plate from rear axle.

Check parking brake shoes for wear and replace if necessary.

See corresponding operation in group H.

Position wheel spindle between two turning centres and check for radial runout.

Permissible runout = 0.05 mm/0.002 in.

Afterwards check wheel spindle for lateral runout.

Permissible runout = 0.05 mm/0.002 in.

Screw wheel spindle to rear axle with parking brake anchor plate and tighten to 50 Nm/36.9 lbf. ft.

Then tighten further by 30° · 5°.

Note:

Mounting surfaces and threads of wheel spindle and parking brake anchor plate must be free of grease, paint or dirt.

Lubricate wheel spindle slightly around parking brake anchor plate with Antifriction Bearing Grease 19 41 574 (90 001 812).

Set disc hub with lock washer on wheel spindle and screw on wheel spindle nut to 25 Nm/18.4 lbf. ft.

Adjust wheel bearing play.

See corresponding operation in this group.

Attach brake caliper and tighten to 65 Nm/47.9 lbf. ft.

Check that brake pads are in perfect condition and show no wear.

See corresponding operation in group H.

Replace brake line in holder.

Unbolt auxiliary stabilizer and remove.

Place auxiliary stabilizer on new rear axle and bolt it on.

Tighten hex nuts to 35 Nm/25.8 lbf. ft.

Disc Brakes and Drum Brakes

Unbolt stabilizer bracket.

Remove stabilizer from rear axle.

If necessary, loosen stabilizer from seating on rear axle with a drift.

Install stabilizer in new rear axle and bolt tight.

Tighten hex nuts to 80 Nm/59.0 lbf. ft.

For Drum Brakes

Unscrew brake drum stop screw and remove brake drum.

If required, press parking brake shoe lever back using a screwdriver through aperture.

Lever off dust cap from wheel hub

Remove split pin from wheel spindle nut and remove nut from spindle.

Remove wheel hub from wheel spindle.

Bend open brake line retaining clamps.

Unscrew and remove brake anchor plates from rear axle arm.

Remove paper seal.

Detach parking brake cable from mounting.

Coat rear of brake anchor plate thinly with Sealing Compound 15 04 200 (8 983 368) in area of paper seal.

Fasten paper seals in place.

Coat fastening screws thinly with Locking Compound 15 10 177 (90 167 347).

Bolt brake anchor plate onto rear axle arm and tighten observe prescribed torque of 28 Nm/20.6 lbf. ft.

Install brake lines, placing them in retaining clamps on rear axle and bending clamps shut.

Rotate adjustment unit on both sides as far as stop.

Coat wheel spindle thinly with Antifriction Bearing Grease 19 41 574 (90 001 812) in area of brake anchor plate.

Place wheel hub and retaining washer on wheel spindle and tighten wheel spindle nut - 25 Nm/18.4 lbf. ft.

Adjust wheel bearing play.

Mount brake drums and screw in stop screws.

On Models 38, 48 (Combo/Astramax)

Lever off dust cap from wheel hub.

Remove split pin from wheel spindle nut and remove nut from spindle.

Remove wheel hub from wheel spindle.

Unscrew brake line from wheel brake cylinder and press out of retaining clips.

Lever off retaining clips for brake lines.

Unscrew and remove brake anchor plate from rear axle arm.

Remove paper seal.

Coat rear of brake anchor plate thinly with Sealing Compound 15 04 200 (8 983 368) in area of paper seal.

Fasten paper seals in place.

Coat fastening screws thinly with Locking Compound 15 10 177 (90 167 347).

Bolt brake anchor plate on to rear axle arm and tighten - 65 Nm/47.9 lbf. ft.

Mount retaining clips on welding pin.

Mount brake lines and insert.

Rotate adjustment unit on both sides as far as stop.

Coat wheel spindle thinly with Antifriction Bearing Grease 19 41 574 (90 001 812) in area of brake anchor plate.

Place wheel hub and retaining washer on wheel spindle and tighten wheel spindle nut - 25 Nm/18.4 lbf. ft.

Adjust wheel bearing play.

Install - all except Models 38, 48 (Combo/Astramax)

Place completed rear axle on hydraulic jack (2 mechanics required).

Place parking brake cable over exhaust muffler.

Raise rear axle and fasten to vehicle underbody.

Place hydraulic jack with workshop-manufactured mount under one rear axle arm and raise slightly.

Insert rear springs with lower rubber damper in spring seat.

Raise axle arm further using hydraulic jack and insert shock absorber in bracket - except Models 35, 36, 45 and 46.

If necessary, align hex bolts using a drift.

Tighten shock absorber fastening bolts to 70 Nm/51.6 lbf. ft.

On Models 35, 36, 45 and 46, tighten hex cap nut to 10 Nm/7.4 lbf. ft.

Lower hydraulic jack.

On Models 35, 36, 45 and 46, bolt bracket for return spring of brake proportioning valve to rear axle.

Press lever of brake proportioning valve forwards (looking in direction of travel) as far as stop.

Move bracket on rear axle far enough for spring to rest against bracket and lever of proportioner without play or tension.

Insert brake pressure hoses in bracket on rear axle and mount retaining plates.

Screw brake pressure lines to brake pressure hoses.

On Models with Drum Brakes

Suspend exhaust rear section from mount on vehicle underbody.

For further details see also group L.

Adjust parking brake cable to dimensions previously measured at bracket on rear axle, hook on fuel tank, bracket on vehicle underbody and in brake cable compensation yoke.

For Disc Brakes

Insert parking brake cable in holder on rear axle.

Press guide sleeve with parking brake cable into holder.

Attach parking brake cable "A" and return spring "B" to brake cable lever.

Grease parking brake cable in area of guide sleeve.

Bleed brake system.

Check brake system for leaks.

See corresponding operation in group H.

Adjust parking brake.

See corresponding operation in group H.

Lower vehicle slightly and install rear wheels.

Lower vehicle, tighten rear wheels - 90 Nm/66.4 lbf. ft.

Use two mechanics to weight vehicle at front seats and tighten rear axle to vehicle underbody - 95 Nm/70.0 lbf. ft.

On vehicles with car level control, inflate system to 80 kPa (0.8 bar)/11.6 psi.

On Models 38, 48 (Combo/Astramax)

Place complete rear axle on hydraulic jack (2 mechanics).

Raise rear axle, if required turn in installation position so that lock on rear spring aligns with aperture of rear axle body.

Attach rear axle to rear springs with U-bracket and tensioning plates - ensure that remaining thread is the same on each side.

The difference between excess thread lengths (arrow) must not be more than max. 3 mm/0.19 in.

Tighten fastening nut - 45 Nm/33.2 lbf. ft.

Mount washer for additional spring and tighten fastening nut - 20 Nm/14.7 lbf. ft.

Note:

Retaining lug on underside of washer must always point towards centre of vehicle.

Insert shock absorber in bracket and tighten fastening bolts - 70 Nm/51.6 lbf. ft.

Lower hydraulic jack.

Mount brake pressure lines to brake lines - note different threads (arrows).

Mount parking brake cable. Mount brake drum.

Lower vehicle slightly and mount and tighten rear wheels.

Adjust rear wheel brakes. See also group H.

Bleed brake system.

Check brake system for leaks.

Adjust parking brake.

See corresponding operations in group H.