Vauxhall Workshop Service and Repair Manuals

Rear Axle, Remove and Install – Models F 08, F 08 & W5L, F 68 – Cast Link Suspension with Drum Brake

  Remove

2.   Lift off plenum chamber seal (1) as far as necessary 3.   Raise covering cap (2) for main brake cylinder 4.   Detach cover (3) of brake fluid reservoir •   seal with MKM-558-10 5.   Remove rear wheels Note:   Mark position in respect of drum hub. •   Disconnect wiring harness plug for ABS (5) on both sides •   Unclip wiring harness plug for ABS from brake lines (arrows) •   Unclip wiring harness plug for ABS from bracket on rear axle (4)

6.   Detach linkage for headlamp range control sensor from bracket on rear axle Note:   For vehicles with Xenon headlights 7.   Unhook parking brake cable, rear, at both sides from the connection piece (1) 8.   Unhook parking brake cable, centre, and parking brake cable, rear, out of guide (2) on rear axle •   Lay parking brake cable aside 9.   Detach rear brake line (5) from rear brake hose (3) on both sides 10.   Remove brake hose from bracket •   Retaining plate (4) remains on brake line

12.   Support rear axle at the trailing link with hydraulic jack on the side to be fitted 13.   Remove fastening bolt for shock absorber (1) on rear axle. 14.   Lower hydraulic jack slowly and remove 15.   Draw rear axle down on the side to be assembled (arrow) until the rear spring (2) can be removed Note:   Note installation position of spring. 16.   Position hydraulic jack on trailing link of rear axle again. •   Lift rear axle with hydraulic jack far enough to enable the shock absorber to be refitted. 17.   Attach shock absorbers to rear axle •   with fastening bolt (3) 18.   Remove rear spring on the other side Note:   Removal takes place in the same way.

19.   Place hydraulic jack under rear axle •   with KM-904 (4), KM-6180-2 (3) and KM-6180-1 (1) Note:   Ensure that the guide bolt (arrow) of KM-6180-2 is seated correctly on both sides in the guide hole in the rear axle. 20.   Detach fastening bolt (2) for shock absorber on both sides 21.   Lift rear axle with the hydraulic jack until the rear axle lies on KM-6180-1 (5). 22.   Detach fastening bolt (6) for trailing link of the rear axle from vehicle underbody •   detach on both sides

24.   Clean outer flanks of the damping bushing •   Grease with red grease in the marked areas

  Install

26.   Attach trailing link of rear axle on both sides to vehicle underbody •   with new fastening bolts and nuts (1) – Only screw fastening bolts on loosely

Important:   To prevent distortion of the damping bushings in the trailing link of the rear axle on the vehicle underbody while driving, the rear axle must be adjusted to the dimension (I) before tightening the fastening bolts to torque. 27.   Raise rear axle Note:   To measure, place measuring stick against spring mount through opening in rear axle. •   with hydraulic jack, KM-904 and KM-6180-2 – Measurement (I): 100 mm ± 5 mm between spring mounting on the rear axle and rear of side member (see illustration) 28.   Tighten fastening bolt (1) of the rear axle on vehicle underbody on both sides •   Tightening torque 50 Nm + 45° +15°

29.   Position rear axle in such a way that both shock absorbers can be fitted on the rear axle •   with hydraulic jack KM-904 (4), KM-6180-2 (3) and KM-6180-1 (1) •   Attach shock absorber to rear axle on both sides – with fastening bolt (2) 30.   Remove hydraulic jack •   with KM-904 , KM-6180-1 and KM-6180-2 31.   Install rear springs - proceed as follows: Note:   The rear springs may only be installed individually, on each vehicle side. 32.   Support rear axle with hydraulic jack (6) at the side to be fitted on the trailing link 33.   Remove fastening bolt for shock absorber (5) on rear axle

34.   Lower hydraulic jack slowly and remove. 35.   Pull rear axle downwards on the side to be fitted (arrow) •   until rear spring (1) can be inserted 36.   Position hydraulic jack on trailing link of rear axle. 37.   Raise rear axle with hydraulic jack •   until shock absorber can be installed on rear axle 38.   Attach shock absorbers to rear axle •   with fastening bolt (2) – Tightening torque 110 Nm 39.   Install rear spring on the other side Note:   Installation takes place in the same way.

40.   Insert brake hose (1) on both sides in brackets on rear axle •   Attach brake line (2) with retaining clamp (3) to brake hoses – Tightening torque 16 Nm 41.   Insert parking brake cable, centre, and parking brake cable, rear, in guide (5) on rear axle •   Attach connecting piece (4) 42.   Clip ABS wiring harness in bracket (6) on rear axle and on to brake line (arrows) •   Connect ABS wiring harness (7) electrically 43.   Attach linkage for headlamp range control sensor to bracket on rear axle Note:   For vehicles with Xenon headlights •   Tightening torque 5 Nm

44.   Attach rear wheels •   Tightening torque 110 Nm 45.   Remove MKM-558-10 (1) from brake fluid reservoir. 46.   Bleed brake system and check for leaks 47.   Seal brake fluid reservoir with sealing cover 48.   Fold down covering cap (2) for brake fluid reservoir 49.   Place seal (3) on plenum chamber