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Rear Brake Rotor Replacement > < Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe

Astra J

Front Brake Rotor Replacement

Special Tools

•  CH-41013   Rotor Resurfacing Kit
•  CH-42450-A   Wheel Hub Resurfacing Kit
•  EN-45059   Angle Meter

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Warning:  Refer to Brake Dust Warning .

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1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
3. Install a C-clamp (1) over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad.
4. Tighten the C-clamp (1) until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.
5. Remove the C-clamp (1).

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6. Remove and DISCARD the brake caliper bracket bolts (1).

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Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.


Note:  Do NOT disconnect the hydraulic brake flexible hose from the caliper.
7. Remove the brake caliper and the caliper mounting bracket as an assembly (1) from the steering knuckle and support the assembly with heavy mechanic's wire, or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose.
8. Mark the position of the brake rotor to the wheel studs.

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9. Remove the brake rotor screw (2).
10. Remove the brake rotor (1) from the wheel hub.

Installation Procedure


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Note:  Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation.
1. Using the CH-42450-A   resurfacer , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange (1).
2. Using the CH-41013   resurfacer , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor (2).
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
4. Install the brake rotor to the hub/axle flange. Use the mark made prior to removal to ensure proper orientation to the flange.

Caution: Refer to Fastener Caution .
5. Install the brake rotor screw and tighten to 7 N·m (62 lb in) .
6. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled LRO of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout Measurement .
7. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction .
8. Remove the support, and install the brake caliper and the brake caliper bracket as an assembly to the steering knuckle.

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9. Install NEW brake caliper bracket bolts (1) and tighten a first pass to 100 N·m (74 lb ft) .
Warning:  Refer to Torque-to-Yield Fastener Warning .
10. Tighten the NEW brake calliper bracket bolts a final pass to an additional 45 to 60 degrees , using the EN-45059   meter .
11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
12. Lower the vehicle.

Rear Brake Rotor Replacement > < Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe