Rear Brake Caliper - Removal, Overhaul And Refitting; Gmf Type Caliper - Opel Kadett Owner's Manual

9•10 Braking system
10.22 Fitting caliper bracket guide springs
- early type ATE caliper
20 When the piston has been partially
depressed, engage the dust excluder with the
rim of the cylinder and fit the retaining clip.
21 Press the piston fully into its cylinder bore.
22 Secure the caliper bracket in a vice and
install the guide springs (see illustration).
23 Slide the caliper body into the bracket
splines until the body and bracket are flush.

GMF type caliper

24 With the caliper on the bench, wipe away
all traces of dust and dirt, but avoid inhaling
the dust as it is injurious to health.
25 Prise the sliding sleeve inner dust caps
from the caliper housing.
26 Push the caliper sliding sleeves inwards
so that the dust caps can be disengaged from
the sleeve grooves and removed.
27 Prise off the piston dust excluder.
28 Remove the piston dust excluder from the
caliper.
29 Carry out the operations described earlier
in paragraphs 10 to 12.
30 Press the sliding sleeves out from the
caliper body, noting which way around they are
fitted, and recover their sealing rings. Inspect
the sleeves and caliper body for signs of wear
or damage. Both should be undamaged and a
reasonably tight, sliding fit in each other.
31 Check all components and renew any that
are worn or damaged. Check particularly the
cylinder bore and piston; these should be
renewed (note that this means the renewal of
the complete body assembly) if they are
scratched, worn or corroded in any way.
32 If the assembly is fit for further use, obtain
the necessary components from your Vauxhalll
dealer. Renew the caliper seals as a matter of
course; these should never be re-used.
33 On reassembly, ensure
components are absolutely clean and dry.
34 Soak the piston and the new seal in clean
hydraulic fluid. Smear clean fluid on the
cylinder bore surface.
35 Fit the new seal using only the fingers to
manipulate it into the cylinder bore groove.
36 Fit the new dust seal to the piston and
refit it to the cylinder bore using a twisting
motion, and ensure that the piston enters
squarely into the bore.
37 When the piston has been partially
depressed, engage the dust excluder with the
rim of the cylinder then depress the piston
fully into its cylinder bore.
38 Fit the new sealing rings to the sliding
sleeve recesses and apply the grease
supplied in the repair kit to the sleeves. Install
the sleeves making sure they are fitted the
correct way around.
39 Fit the inner dust caps, making sure they
are correctly engaged with the sliding sleeves.
Slide the sleeves into position and press the
dust caps into position on the caliper body
using a suitable tubular drift.
Later ATE type caliper
40 With the caliper on the bench, wipe away
all traces of dust and dirt, but avoid inhalling
the dust as it is injurious to health.
41 Press the sliding bolt sleeves out of their
bore in the caliper body.
42 Carry out the operations described in
paragraphs 10 to 19, positioning the piston as
shown in illustration 4.23.
43 Ensure that the dust excluder is correctly
located in the caliper body then coat the new
slide bolt sleeves with washing-up liquid and
press them into their bores by hand.
Refitting
44 On GMF and early ATE type calipers, prior
to refitting, remove all traces of locking
compound from the caliper mounting bolt
threads and the hub carrier holes. Apply a
drop of fresh locking compound to the bolt
threads. Refit the caliper and insert the
mounting bolts, tightening them to the
specified torque setting.
45 On all calipers, refit the brake pads as
described in Section 4 but do not depress the
brake pedal yet.
46 Position a new sealing washer on each
side of the hose union and connect the brake
hose to the caliper. Ensure that the hose is
correctly positioned against the caliper body
lug then install the union bolt and tighten it to
the specified torque setting.
47 Remove the brake hose clamp or
polythene, where fitted, and bleed the
hydraulic system as described in Section 2.
Note that providing the precautions described
were taken to minimise brake fluid loss, it
should only be necessary to bleed the
relevant front brake.
48 Refit the roadwheel, aligning the marks
made on removal, then lower the vehicle to
the ground and tighten the roadwheel bolts to
the specified torque.
that all
11.5 Removing the rear caliper
11 Rear brake caliper - removal,
overhaul and refitting
Note: Before starting work, refer to the note at
the beginning of Section 2 concerning the
dangers of hydraulic fluid and to the warning
at the beginning of Section 5 concerning the
dangers of asbestos dust.
Removal
1 Apply the handbrake, then jack up the rear
of the vehicle and support it on axle stands
(see "Jacking and Vehicle Support"). Remove
the appropriate roadwheel, marking its correct
fitted position on the wheel hub.
2 Minimise fluid loss either by removing the
master cylinder reservoir cap and then
tightening it down onto a piece of polythene
to obtain an airtight seal, or by using a brake
hose clamp, a G-clamp or a similar tool to
clamp the flexible hose at the nearest
convenient point to the rear brake.
3 Clean the area around the caliper brake
pipe union. Unscrew the union nut and
disconnect the pipe from the caliper. Plug the
pipe end and caliper hole to minimise fluid
loss and prevent the ingress of dirt into the
hydraulic system.
4 Remove the brake pads as described in
paragraphs Section 5.
5 Slacken and remove the two caliper
mounting bolts and remove the caliper
assembly from the vehicle (see illustration).
Overhaul
Note: No attempt must be made to separate
the caliper halves. If overhaul cannot be
accomplished with the caliper assembled, it
must be renewed.
6 With the caliper on the bench, wipe away all
traces of dust and dirt, but avoid inhaling the
dust as it is injurious to health.
7 Prise off the piston dust excluders.
8 Clamp one of the pistons in its bore using a
G-clamp and a thin piece of wood then
extract the opposite piston and associated
components as described in paragraphs 9 to
20 of Section 10, position the piston step as
shown (see illustration).
11.8 Correct position of rear caliper piston
step, showing the inboard piston on the
right-hand caliper. Opposite piston is the
mirror image