Disc pads — inspection and replacement (Opel Ascona C)

1. Raise the front of the machine. If the wheels were balanced directly on the car (new machines are balanced in this way during production), then note the relative position of the wheel to the hub so that it can be positioned correctly during assembly.

2. Inspect the thickness of the friction material on each pad. If any one of them has a thickness that meets or is below the specified minimum, then replace the entire set (four pads) as follows.



3. Press out the pins holding the pads by pressing on their inner ends with a punch.



4. Remove the springs (photo).





5. Using a pair of pliers, pull out the outer shoe (photo).



6. Remove the inner shoe. If it is very tight, then move the shoe slightly to the side to press on the caliper piston (photo).



7. To install new, thicker pads, you need to press the caliper piston all the way into its cylinder using a flat metal rod, such as a tire lever. Pushing the piston will cause the fluid in the reservoir to rise, so anticipate this by pumping out some fluid using an old (clean) hydrometer or something similar.

8. Brush the caliper cheeks without inhaling the powder.

9. Insert the pads, making sure the lining side is against the disc. If you are installing disc pads made by the vehicle manufacturer, you may find that two of the four pads have white marks on their back plates. If this is the case, the pads with the marks should be installed on the piston sides of the calipers. On new ATE type brake assemblies a washer may be installed between the inner brake shoe and the caliper piston. In this case, make sure that the washer is inserted with the inner shoe (photo).





10. Position the expansion springs correctly (Figure 9.3), and then insert the retaining pins (photo).





11. Repeat these steps on the opposite brake.

12. Install the wheels and lower the car.



13. Press the brake pedal firmly several times to ensure that the pads are correctly positioned relative to the discs.

14. Add liquid to the reservoir to the required level.

15. New brake pads need to be bedded in, so avoid hard braking if possible during the first 120 miles (200 km).