Vauxhall Workshop Service and Repair Manuals

Rear Axle, Remove and Install – Models F 08, F 68 (Cast Link Suspension with Disc Brake)

  Remove

3.   Lift off seal (1) on plenum chamber as far as necessary. 4.   Raise covering cap (2) of main brake cylinder 5.   Detach cover (3) of brake fluid reservoir •   seal with MKM-558-10 6.   Remove rear wheels Note:   Mark position relative to wheel hub. •   Disconnect wiring harness plug for ABS (5) on both sides •   Unclip wiring harness plug for ABS (5) from brake lines (arrows) •   Unclip wiring harness plug for ABS (5) from bracket on rear axle (4)

7.   Detach linkage for headlamp range control sensor from bracket on rear axle Note:   For vehicles with Xenon headlights 8.   Detach rear parking brake cable (1) out of lever for parking brake (2) on both sides 9.   Detach retaining plate (4) for parking brake cable on both sides from counterhold (3) 10.   Remove parking brake cable out of counterhold and guide on rear axle (5) 11.   Detach rear brake line (6) from rear brake hose on both sides of rear axle 12.   Remove brake hose from bracket •   Retaining plate (7) remains on brake line

14.   Support rear axle at the trailing link with hydraulic jack on the side to be fitted 15.   Remove fastening bolt for shock absorber (1) on rear axle. 16.   Lower hydraulic jack slowly and remove 17.   Pull rear axle downwards on the side to be fitted (arrow) •   until the rear spring (2) can be removed Note:   Note installation position of spring. 18.   Position hydraulic jack on trailing link of rear axle. 19.   Lift rear axle with hydraulic jack far enough to enable the shock absorber to be fitted 20.   Attach shock absorbers to rear axle •   with fastening bolt (3)

22.   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. 23.   Detach fastening bolt (2) for shock absorber on both sides. 24.   Lift rear axle with the hydraulic jack until the rear axle lies on KM-6180-1 (5) 25.   Detach fastening bolt (6) for trailing link of the rear axle from vehicle underbody •   detach on both sides

27.   Clean outer flanks of the damping bushing and - see "Technical Data" •   Grease with red grease in the marked areas Note:   Illustration shows cast link suspension with drum brake.

  Install

29.   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. 30.   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) 31.   Tighten fastening bolts (1), rear axle, on vehicle underbody on both sides •   Tightening torque 50 Nm + 45° + 15°

32.   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) 33.   Attach shock absorbers on both sides of rear axle •   with fastening bolt (2) 34.   Remove hydraulic jack •   with KM-904 , KM-6180-1 and KM-6180-2 35.   Install rear springs - proceed as follows. Note:   The rear springs may only be installed individually, on each vehicle side. 36.   Support rear axle at the trailing link with hydraulic jack (6) on the side to be fitted 37.   Remove fastening bolt for shock absorber (5) on rear axle

38.   Lower hydraulic jack slowly and remove 39.   Pull rear axle downwards on the side to be fitted (arrow) •   until rear spring (1) can be inserted 40.   Position hydraulic jack on trailing link of rear axle. 41.   Raise rear axle with hydraulic jack •   until shock absorber can be installed on rear axle 42.   Attach shock absorbers to rear axle •   with fastening bolt (2) – Tightening torque 110 Nm 43.   Install rear spring on the other side Note:   Installation takes place in the same way.

44.   Insert brake hose (1) on both sides in bracket on rear axle body •   Attach brake line (3) with retaining plate (4) on brake hose – Tightening torque 16 Nm 45.   Insert rear parking brake cable on both sides in the guide (2) on the rear axle and counterhold (7) on the brake calliper 46.   Suspend parking brake cable (5) on the lever for the parking brake (6) 47.   Attach retaining plate (8) for parking brake cable on counterhold on brake calliper 48.   Clip ABS wiring harness into bracket (9) on rear axle body and on the brake line (arrows) •   Connect ABS wiring harness (10) electrically 49.   Attach linkage for headlamp range control sensor to bracket on rear axle Note:   For vehicles with Xenon headlights •   Tightening torque 5 Nm

50.   Attach rear wheels •   Tightening torque 110 Nm 51.   Remove MKM-558-10 (1) from brake fluid reservoir. 52.   Bleed brake system and check for leaks 53.   Seal brake fluid reservoir with sealing cover 54.   Fold down covering cap (2) for brake fluid reservoir 55.   Place seal (3) on plenum chamber