Vauxhall Workshop Service and Repair Manuals

GMF Version

Remove brake pads.

Lever off both inner protective caps for sliding sleeve from housing using chisel.

Lever off protective cap for piston using chisel.

Press sliding sleeve inwards slightly - towards protective cap and remove protective cap from groove in sliding sleeve.

Remove protective cap for piston from housing.

Press sliding sleeves out of housing.

Remove piston.

Insert piece of hard wood, approx. 15 to 20 mm/0.6 to 0.8 in. hick, into brake caliper shaft. Press piston out of housing with compressed air until it contacts wood.

Remove piston from housing.

Clamp brake caliper in vice in such a way that retaining frame can be removed.

Unbolt retaining frame from housing and remove.

Lever seal ring out of housing bore using plastic wedge.

Clean piston and bore with alcohol or brake fluid and check for wear.

Work involving removal of material from piston and cylinder is not permitted.

Replace damaged parts except piston.

Always replace parts subject to wear.

If any part is rusted, replace complete brake caliper.

Thinly coat housing bore, piston and seal ring with brake cylinder paste.

Install seal ring and piston.

Carefully insert piston in cylinder bore.

When doing so, ensure that piston does not jam and that seal ring is properly seated in groove.

Do not insert piston in bore as far as stop, since protective cap is then difficult to install.

Insert protective cap for piston in groove and press onto housing.

Install protective cap as far as stop on housing using KM-405.

Clamp housing in vice. Mount retaining frame and tighten observe prescribed torque of 95 Nm/70.07 lbf. ft.

Lever seal rings for sliding sleeves out of groove on sliding sleeve using plastic wedge.

Before mounting seal ring, thinly coat sliding sleeve with special grease enclosed in repair set.

Push seal ring on to sliding sleeve and insert in groove in centre of sliding sleeve.

Ensure that seal ring is not twisted in groove.

Insert sliding sleeve in housing so that groove (arrows) for inner protective cap faces piston.

Do not insert sliding sleeves until flush, but only so far that protective caps can be installed.

Insert inner protective caps in grooves of protective sleeves and press on to collar on housing.

Then push protective caps on using KM-404-3 and KM-404-4 until they rest on housing.

Note: Always use new protective caps.

Push sliding sleeves further into housing at centre.

Install brake pads.

Ensure retaining pins and expanding springs are correctly installed.

Note: Mount retainers, if available.