Vauxhall Workshop Service and Repair Manuals

Replace brake pads on rear wheel brake

Note:   All the brake pads on one axle must be replaced as a matter of principle.

  Remove

1.   Release parking brake cable •   Release parking brake lever •   Detach cover of diagnostic connection •   Detach parking brake bellows •   Release parking brake cable by unscrewing adjusting nut 2.   Remove rear wheels 3.   Detach parking brake cable from brake calliper •   Press brake calliper actuating lever (1) downwards in direction of arrow using screwdriver (2) and detach parking brake cable. Note:   Ensure that dust sleeve between actuating lever and brake calliper is not damaged. •   Remove retention clip (3) and pull parking brake cable (4) out of bracket

4.   Remove brake pads from brake calliper •   Detach bolt (1) from brake calliper – - counterhold using open-ended wrench (2) •   Fold brake calliper upwards

5.   Unscrew brake piston Note:   Brake fluid level increases in brake fluid reservoir. Remove brake fluid with siphon bottle if necessary. •   Position KM-6007-A (2) on brake calliper with KM-6007-30 (1) – Push KM-6007-30 over KM-6007-A Note:   Ensure that the collar (arrow) of KM-6007-30 points towards the hand wheel or hexagonal section of KM-6007-A •   Unscrew the brake piston as far as the stop - then pull it out of the brake calliper until the next cutout (3) in the brake piston is flush with the opening on the brake calliper.

6.   Remove the brake calliper from the brake support Note:   The brake calliper must be completely removed from the brake carrier before mounting the brake pads. •   Detach upper bolt from brake calliper – - counterhold using open-ended wrench •   Detach the brake calliper from the brake carrier. – Suspend it from the rear spring with a suitable wire. 7.   Take out brake pads and guide plates (1)

  Clean

8.   Clean guides for brake pads in the top and bottom of the brake carrier (2) and contact surfaces with brake pads on the brake piston (1) and the opposing surfaces (arrows). Note:   Make sure that residues of adhesive on the brake pad surfaces are removed and the surfaces cleaned afterwards.

  Install

Important:   Replace brake calliper and/or brake carrier if the brake calliper is leaking, protective cap on piston is damaged or sealing sleeve on the brake carrier is damaged 10.   Insert new metal guide sheets in brake carrier •   Apply grease to brake carrier below the metal guide sheets (marked surfaces - enlargement 1). •   Insert metal guide sheets (2)

Important:   The protective film (1) on the back of the brake pads must be removed after inserting the brake pads. Brake pad with mechanical wear indicator (if present) must be on the inside. 11.   Insert new brake pads in brake carrier

12.   Attach brake calliper to brake carrier •   Place brake calliper on brake carrier. Note:   Make sure that the sheet metal guides are not bent and the adhesive surfaces of the brake linings only contact the brake calliper after they have been correctly positioned. – Slide the brake calliper exactly in direction of arrow, from back to front, on brake carrier. •   Attach brake calliper bolts to brake carrier – Clean thread and insert new bolts with locking compound – - counterhold using open-ended wrench – Tightening torque 25 Nm

13.   Attach parking brake cable to brake calliper •   Attach parking brake cable to bracket with retaining clip (2) •   Press actuating lever (1) downwards in direction of arrow using screwdriver and attach parking brake cable.