Rear Brake Caliper Repair (Opel Frontera B)

Disassembly

Remove the rear brake caliper (see the relevant chapter).

Using a small screwdriver, remove the dust seal ring from the caliper.



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Remove 2 dust covers (2), bleeder cap (2), ring (3) and seal (4).



Remove the piston from the caliper. To do this, place a wooden block between the piston and the inside of the caliper body. To remove the protective boot and piston, apply compressed air to the brake hose hole.

Warning:

• If air is suddenly supplied to the brake cylinder body, the piston will fly out, damaging the caliper body.
• Apply compressed air gradually. When pushing the piston out with compressed air, do not place your fingers in front of the piston.
• Be careful, as the brake fluid will be blown out of the channel by compressed air along with the piston.

Discard the 2 dust boots (1), ring (3), seal (4) and piston seal ring (6).

Examination

Clean the bleed nipple (2), piston (5) and caliper body (7).

Check the caliper cylinder for wear, damage or rust. Minor rust damage can be removed by polishing with fine grit sandpaper.

Check the piston surface for wear, damage or rust.

Check the caliper body, guide pins and bushings for wear.

Assembly

Insert the piston seal into the cylinder groove.

Lubricate the caliper cylinder with a special lubricant.

Warning: To avoid damaging the cylinder walls and piston seals, use only finger pressure when lubricating.

Apply 1 gram of special lubricant to the piston and install the piston into the cylinder.



Install the seal (2) and ring (1) on the piston.



Apply 1 gram of special lubricant to the inner surface of the dust covers.





Install 2 dust covers on the caliper.



Screw the bleed nipple into the caliper and tighten it to 8 Nm.



Install the caliper onto the brake pad guide.

Apply special lubricant to the lock bolt (2), guide bolt (1) and into the brake shoe guide holes.



Screw in the locking (2) and guide bolt (1) and tighten them to a torque of 44 Nm.



Fill the brake fluid into the hydraulic drive of the brake system and remove air from it (see the relevant chapter).

Warnings:

• Fill the brake system with new DOT 4 brake fluid only.
• Do not use fluid that has been drained from the brake system, as it is saturated with air, contains a lot of moisture and may be contaminated.

Install the wheel and secure with nuts, tightening them to a torque of 118 Nm.