Vauxhall Workshop Service and Repair Manuals

Rear Axle, Remove and Install

Note:   When lifting at the jacking points on the vehicle, take care that all rear axle bolts and the contact points for the centring device remain accessible.

  Remove

1.   In vehicles with drum brake: top up brake fluid reservoir as far as "MAX" marking and seal with MKM-558-10 2.   Release handbrake •   Release handbrake lever (1) •   Detach gaiter of handbrake lever(2) •   Slacken handbrake cable by turning back the adjusting nut (3)

4.   In vehicles with disc brakes: detach 2x handbrake cables from brake caliper •   Push down 2x operating levers (1) at brake caliper with screwdriver •   Detach 2x handbrake cables •   Remove 2x retaining clips (2) •   Pull 2x handbrake cables out of bracket 5.   In vehicles with drum brakes: disconnect 2x handbrake cables (4) from connecting piece (3)

9.   Attach 2x rear axle mounting to KM-6002-A on Astra-H model L 48, L 08 and L 67 •   Tighten 2x bolt Note:   Note installation position (arrow)!

10.   Attach 2x rear axle mounting to KM-6002-A on Astra-H estate (L 35, L 70) •   Attach KM-6002-300 (1), (arrow) to KM-6002-A Note:   Installed position of KM-6002-300 (1), (arrow) •   Tighten 2x bolt (2) •   Attach rear axle mounting – Tighten 2x bolt

11.   On Astra-H convertible (L67): Remove right and left torsion struts •   Unscrew 14x bolt 12.   Clean thread •   Clean 14 threads

13.   Place hydraulic jack KM-904 connected to KM-6000-A and erect Note:   Due to the changed position of guide holes on the vehicle underbody, KM-6000-400 (1) must be fitted to KM-6000-A for Astra-H notchback (L 69). The plastic cap (2) of KM-6000-400 (1) must point outwards.

14.   Detach 2x shock absorbers (2) from rear axle •   Unscrew 2x bolt 15.   Lower hydraulic jack carefully until rear axle is freely suspended. 16.   Remove springs •   Remove 2x springs •   Remove 4x damping rings Note:   Note installation position of damping rings. Important:   The bolts must not be removed from the rear axle bracket using an impulse or impact screwdriver. 17.   Detach rear axle Warning:   Ensure that the vehicle does not lift from the lifting platform attachment points. •   Support rear axle by raising the hydraulic jack •   Unscrew 6x bolts (3) from vehicle underbody 18.   Lower hydraulic jack completely with rear axle.

  Install

19.   Check thread of the cage nuts on the vehicle underbody for damage. 20.   Pull out the guides (1) of KM-6002-A (3) and arrest with the locking pins (2). 21.   Attach rear axle to vehicle underbody •   Lift rear axle with hydraulic jack, KM-904 and KM-6002-A Note:   Both front guides of KM-6002-A must rest in the guide holes with the collar and both rear axle brackets on the vehicle underbody •   Screw in 6x new bolts Note:   The rear axle bracket bolts must not be installed using an impulse or impact screwdriver.

22.   Lift rear axle with hydraulic jack, KM-904 and KM-6002-A until distance measurement I = 173 ± 10 mm between the spring mounting of the rear axle and the spring mounting of the vehicle underbody. Distance measurement I must be the same on both the right and left side.

23.   If the bolted joint on the rear axle bracket on the damping bush is undone: tighten new bolted joint (1) on the rear axle bracket on the damping bush ( 90 Nm + 60° + 15° )

24.   Tighten 6x new bolt (1) on the rear axle bracket on the vehicle underbody ( 90 Nm + 30° + 15° ) 25.   Attach springs •   Draw out locking pins (3) and push in guides (2) of KM-6002-A (4) •   Lower hydraulic jack until rear axle is freely suspended •   Attach 4 damping rings to springs •   Insert 2x springs Note:   Note installation positions. 26.   Attach shock absorbers to rear axle •   Raise rear axle until both shock absorbers (5) can be attached to rear axle Note:   Ensure that the vehicle does not lift from the lifting platform attachment points. •   Tighten 2x bolt 130 Nm Note:   For vehicles with level control: push pressure line or connection piece on to connection on shock absorber - ensure retaining clamp sits perfectly. 27.   Lower hydraulic jack and remove. 28.   On Astra-H convertible (L67): Install left torsion strut •   Tighten 7x bolt 65 Nm 29.   On Astra-H convertible (L67): Install right torsion strut •   Tighten 7x bolt 65 Nm 30.   In vehicles with disc brakes: attach 2x brake anchor plate •   Attach brake anchor plate •   Tighten 4x bolts 100 Nm Note:   Clean thread and insert fastening bolt with bolt locking compound! •   If removed: install brake linings 31.   In vehicles with drum brakes: attach 2x brake hose to vehicle underbody •   Insert 2x brake hose into bracket on vehicle underbody •   Secure 2x brake hoses with retaining plate •   Attach 2x brake line to brake hose 16 Nm 32.   Attach wheel sensor wiring harness to rear axle •   Connect 2x wheel sensor wiring harness plugs •   Clip in 8x wiring harnesses

33.   In vehicles with disc brakes: attach handbrake cable to brake caliper •   Insert 2x handbrake cables into bracket on brake caliper •   Attach 2x retaining clips (2) to handbrake cable •   Push down 2x operating levers (1) at brake caliper with screwdriver •   Attach 2x handbrake cables 34.   In vehicles with drum brake: connect 2x handbrake cables (4) with connecting piece (3)

36.	In vehicles with drum brakes: fill and drain brake system •   Fill with brake fluid to "MAX" mark •   Screw cover to brake fluid reservoir