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Rear Brake Caliper Hardware Replacement > < Rear Brake Caliper Vibration Dampener Replacement

Astra J

Rear Brake Caliper Replacement (with Dampener)

Removal Procedure

Warning:  Refer to Brake Fluid Irritant Warning .

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

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6. Remove the brake hose to caliper bolt (2) from the brake caliper.
7. Remove the brake hose (1) from the brake caliper.
8. Remove and discard the 2 copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end.
9. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination.

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10. Remove the upper brake caliper pin bolt (1).
11. Remove the brake caliper vibration dampener (3).

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12. Remove the park brake cable from the rear parking brake lever (1).
13. Remove the brake caliper from the brake caliper bracket.

Installation Procedure

1. Inspect the caliper slide boots for cuts, tears, or deterioration. If damaged, replace the slides and boots. Refer to Rear Brake Caliper Hardware Replacement .

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2. Install the brake caliper to the brake caliper bracket.

Caution: Refer to Fastener Caution .
3. Install the lower brake caliper pin bolt (1) and tighten to 28 N·m (20 lb ft) .
4. Install the brake caliper vibration dampener (3) and tighten to 28 N·m (20 lb ft) .

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5. Install the park brake cable to the rear parking brake lever (1).

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6. Remove the caps or plugs from the brake caliper opening and the brake hose.

Note:  DO NOT reuse the copper brake hose gaskets.
7. Install NEW copper brake hose gaskets (3) to the brake hose-to-caliper bolt (2) and to the brake hose.
8. Install the brake hose and the brake hose-to-caliper bolt to the brake caliper and tighten the bolt to 40 N·m (30 lb ft) .
9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .
10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
11. Slowly release the brake pedal.
12. Wait 15 seconds, then repeat steps 9 and 10 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
13. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
14. Lower the vehicle.
15. Apply and release the park brake lever 4 times.

Rear Brake Caliper Hardware Replacement > < Rear Brake Caliper Vibration Dampener Replacement