Subject:
Squeaking noises at rear wheel brake
Vehicles:
All Astra-G and Zafira models with rear wheel disc brakes
Condition:
1. Parking brake actuation sticking
2. Squeaking noises at rear wheel brake with brake actuation
3. Squeaking noises at rear wheel brake without brake actuation
Cause:
1. Parking brake actuation sticking at brake caliper of rear wheel disc brake due to inadequate greasing of brake caliper inner parts.
2. The brake lining material used in the rear brake linings can vibrate under light brake actuation and this can result in squeaking noises.
3. Seizing, tilting or canting of the brake linings in the brake lining guides.
Remedy:
Due to the complaints described in "Condition", various modifications were performed to the brake calipers, brake linings and brake discs which have been introduced into production as of the following VINs:
Production location VIN
Ellesmere Port WOLOTGF35 Y8077977
Eisenach WOLOTGF48 Y6069184
Bochum I WOLOTGF35 Y2157390
Bochum I WOLOTGF75 Y2158623
Antwerp WOLOTGF48 Y5154289
Note: Before beginning the relevant operations, it is essential to determine whether the squeaking noises are coming from the front wheel brake or the rear wheel brake.
If the noises are coming from the front wheel brake, only these brake linings must be replaced.
In the case of noises from the rear wheel brake, these should be eliminated as described below. For this purpose, the brake caliper version fitted must always be taken into account.
Condition 1 — parking brake actuation sticking
Check correct operation of parking brake at brake caliper:
For this purpose, disengage parking brake cable from brake caliper actuating lever (1).
Press actuating lever downwards with screwdriver.
If depressing the actuating lever requires excessive force or is not possible at all, then the affected brake caliper, the associated brake linings and the brake linings of the brake caliper which is not affected must be replaced as described in the Astra-G, Zafira Service Instructions, group H.
| If, during this operation, excessive wear of the brake disc is detected, both brake discs must be replaced. | |||
|---|---|---|---|
| .P. H2923.tif | 9 | 7,5 | tiff;; |
When replacing the brake caliper, the relevant brake caliper version and parking brake cable version must be taken into account.
Before installing the brake linings, Catalogue No. 16 05 093, Part No. 9 198 598, the brake lining contact points on the brake carrier must be cleaned using a wire brush and then thinly coated with the grease supplied in the lining kit.
Note: As the squeaking noises occur under varying conditions, we will differentiate between with brake actuation — 2 and without brake actuation — 3 in future complaints.
Condition 2 — squeaking noises at rear wheel brake with brake actuation
In the case of this complaint, the brake linings, Catalogue No. 16 05 093, Part No. 9 198 598 of the rear wheel disc brake must generally be replaced.
For this purpose and before installing the brake linings, the brake lining contact points on the brake carrier (arrows and shading) must be cleaned using a wire brush and then thinly coated with the grease supplied in the lining kit.
| Note: In addition for vehicles with 4-hole wheel rims, the brake discs must be replaced as described in the Astra-G, Zafira Service Instructions, group H. | |||
|---|---|---|---|
| .P. H2924.tif | 9 | 16 | tiff;; |
Condition 3 — squeaking noises at rear wheel brake without brake actuation
Brake linings seized in brake caliper
If the brake linings are seized in the brake lining guides, they must also be removed using excessive force.
If, during this operation, excessive wear of the brake discs is detected, they must be replaced as described in the Astra-G, Zafira Service Instructions, group H.
Before installing the brake linings, Catalogue No. 16 05 093, Part No. 9 198 598, the brake lining contact points on the brake carrier must be cleaned using a wire brush.
This area must then be thinly coated with the grease supplied in the lining kit.
Brake linings not seized in brake caliper
In the case of this complaint, the affected brake caliper must be replaced. For this purpose, the relevant brake caliper version and parking brake cable version must be taken into account.
The relevant operations can be found in the Astra-G, Zafira Service Instructions, group H.
| Before installing the brake linings, Catalogue No. 16 05 093, Part No. 9 198 598, the brake lining contact points on the brake carrier must be thinly coated with the grease supplied in the lining kit. | |||
|---|---|---|---|
| .P. H2924.tif | 9 | 16 | tiff;; |
Note:
If the brake linings of the rear wheel disc brake were replaced recently and repeated complaints due to "faintly audible squeaking noises" are received, then the brake linings must be removed. The brake lining contact points on the brake carrier must be cleaned and thinly coated with grease, Catalogue No. 19 48 600, Part No. 9 163 321.
Parts:
| Designation | Part Number | Catalogue Number |
|---|---|---|
| Brake linings for rear disc brake | 9 198 598 | 16 05 093 |
| Brake caliper for rear left disc brake, piston diameter: 34 mm | 9 196 452 | 5 42 304 |
| Brake caliper for rear right disc brake, piston diameter: 34 mm | 9 196 453 | 5 42 305 |
| Brake caliper for rear left disc brake, piston diameter 36 mm | 9 196 454 | 5 42 306 |
| Brake caliper for rear right disc brake, piston diameter: 36 mm | 9 196 455 | 5 42 307 |
| Brake caliper for rear left disc brake, piston diameter 38 mm | 9 196 456 | 5 42 308 |
| Brake caliper for rear right disc brake, piston diameter: 38 mm | 9 196 457 | 5 42 309 |
| Set of rear brake discs, 240 x 10 mm | 9 196 587 | 5 69 111 |
| Set of rear brake discs, 264 x 10 mm | 9 117 772 | 5 69 109 |
| Grease, Molycote M111 | 9 163 321 | 19 48 600 |
Time Allowance:
Op. no. Description hrs
T0 610 00 Replace rear brake calipers and brake linings 1.2
TC: 92
+: Clean guides and contact surfaces, adjust travel of parking brake
release lever, grease guides, bleed brake system
and check for leaks
001 Replace brake discs .4
T0 610 20 Replace brake linings .7
TC: 92
+: Clean guides and contact surfaces, adjust travel of parking brake
release lever and grease guides.
001 Replace brake discs (in conjunction with 4-hole wheel rims) .4
T0 610 30 Clean brake calipers and replace brake linings .9
(applies to seized brake linings)
TC: 92
+: Clean guides and contact surfaces, adjust travel of parking brake
release lever and grease guides.
001 Replace brake discs .4
T0 610 40 Replace one rear brake caliper and 1.1
replace brake linings of both brake calipers
TC: 92
+: Clean guides and contact surfaces, adjust travel of parking brake
release lever, grease guides, bleed brake system
and check for leaks.
001 Replace brake discs .4
Important:
The specified time allowances do not include the time allowance for the vehicle set-up of .2 hrs.
For reimbursement of the vehicle set-up time of .2 hrs in warranty claims, enter the authorisation code ”T” and increase the main operation time allowance by .2 hrs.