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BRAKE
DISC, BRAKE CALIPER
Brake
Pads, Remove and Install or Replace
Rear
Wheel Brake
Note:
All
brake pads and expanding springs of one axle must be replaced.
Remove
Raise
vehicle.
Remove
rear wheels.
Mark
position of rear wheel relative to hub.
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Drive
brake pad retaining pins out of brake caliper from outside inwards.
Note
released expanding springs "A".
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Remove
brake pads from brake caliper shaft; if necessary, use brake pad impact
remover, commercially available.
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Press
piston back in housing using piston pusher, commercially available.
Note:
Because
of large volume of bore in housing, when piston is pushed in, brake fluid
level in reservoir will increase. If necessary, drain brake fluid.
Clean
brake caliper shaft using suitable soft wire brush.
On
no account use sharp-edged tools or cleaning material containing mineral oil,
otherwise the piston protective cap will be damaged.
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Measure
thickness of brake disc.
Each
time brake pads are replaced, measure remaining thickness of brake disc using
KM-230 and check surface condition of disc.
The
remaining thickness of the brake disc must be at least 8 mm/0.315 in.
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If a defect in the protective
caps of the pistons is discovered while carrying out these operations, replace
the caps.
This
is described as part of the operation "Brake Caliper, Overhaul" in this
group.
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Install
Check
piston position using piston adjustment gauge, commercially available.
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If
necessary, correct piston position using piston turning pliers, commercially
available.
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Only
use genuine Opel brake pads. When installing, check that pad can be moved
slightly backwards and forwards in guide.
If
necessary, thinly coat side support of brake pad backplate with Grease 19 42
585 (90 113 123).
Insert
brake pads into brake caliper.
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Install
retaining pins "B" from inside outwards together with
expanding spring "A" as shown in illustration.
Replace
brake pads and expanding springs on the other side in same way.
Set
rear wheels to position marked previously and tighten wheel bolts - 90
Nm/66.4 lbf. ft.
Lower
vehicle and adjust clearance by repeatedly fully depressing brake pedal.
Correct
level of brake fluid in reservoir to "MAX".
Instruct
vehicle owner not to brake hard for approximately 200 km/120 miles if this
can be avoided.
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