Checking Brake Disc For Lateral Runout; Major Repair; Removing And Installing Brake Caliper; Removing And Installing Brake Disc - Opel 1900 1973 Service Manual

a tine cut file. Do not use any solvent except dena-
tured alcohol. Do not use a metaIJic scraper too/.
8. With a punch, drive one dowel pin from inboard
side through caliper and friction pads to stop. Install
new cross-shaped retaining spring under installed
dowel pin, then install second dowel pin. Loose tit-
ting dowel pins must be replaced.
9. Before operating vehicle, depress brake pedal sev-
eral times to adjust friction pads to brake discs.
Check brake fluid level and add fluid as necessary to
bring level up to "MAX" on reservoir.
Car owners must be informed that a break-in period
exists for new friction pads, and that they must avoid
unnecessary, forceful braking during the first 125
miles after installation of new friction pads.

Checking Brake Disc for Lateral Runout

1. Remove front wheel assembly.
2. Remove front wheel bearing hub cap and spindle
nut cotter pin. Tighten spindle nut until all free play
is removed from wheel bearings.
3. To check disc runout, use Dial Indicator Set J-
joint attaching bolt as shown in Figure 5B-27. Posi-
tion dial indicator button against brake disc l/2 inch
from outer circumference.
Figure 58-27 Checking Brake Disc Lateral Runout
4. Rotate disc, reading maximum dial indicator
movement. Maximum permissible runout
inch.
5. If runout exceeds 0% inch, remove disc and hub
assembly and true disc in a suitable disc turning
lathe, following manufacturer's instructions. The
depth of cut on each side of disc should be just deep
enough to get a true flat surface.
6. After truing disc on both sides, check thickness
with a micrometer. A disc with a thickness of less
than ,394 inch is liable to warp after hard braking
and, therefore, must be discarded.
7. Reinstall brake disc and hub assembly, removing
all play from wheel bearings. Repeat runout
If runout still exceeds ,001 inch, replace brake disc.
8. Adjust front wheel bearings.
9. Reinstall front wheel assembly.

MAJOR REPAIR

REMOVING AND INSTALLING BRAKE CALIPER

1. Remove left or right front wheel and remove fric-
tion pads from brake caliper.
2. Loosen brake line to brake caliper union nut sev-
eral turns. Unscrew brake caliper plus brake hose
bracket from steering knuckle. Remove it from brake
disc and swing it sideways. Then unscrew brake pipe
from brake hose and remove brake caliper and brake
pipe (bent pipe). To prevent brake fluid loss, close
brake hose with a plug.
3. Prior to installation, check contacting surfaces of
the brake caliper and steering knuckle to make sure
they are free of any burrs and dirt.
4. Install brake caliper on steering knuckle and
torque attaching bolts to 72 lb.ft. See Figure 5B-28.
CAUTION: This disc brake cah@er attachments fas-
tener is an important attaching part in that it could
affect the performance of vital components and sys-
tems, a,ld/or could result in major repair expense. It
must be replaced with one of the same part number
necessary. Do not use a replacement part of Jesser
used as specitied during reassembly to assure proper
retention of this part.
5. Attach brake pipe to brake hose.
6. Install friction pads and replace wheel.
REMOVING
is ,004
BRAKE DISC
DISC BRAKES
AND INSTALLING
check.