Up to VIN _188104

Removal
1. Remove one road wheel nut and mark the stud to wheel relationship. Remove the remaining nuts and remove the road wheel.
2. Remove the nuts and bolts securing the tie-plate to the rear suspension unit; remove the tie- plate.





3. Ensure that the handbrake lever is in the fully OFF position. Lift the carpet adjacent to the handbrake lever mounting for access to the cable adjusting nuts(1 Fig. 1). Loosen the cable lock/adjusting nuts.





4. Release the springs (1) from the handbrake caliper arms. Move the right-hand arm (when viewed from the rear of the car) to the center line of the car, enabling the end of the inner (operating) cable (2) to be detached from the operating arm.
5. Slide the rubber cover from the outer cable (3) and release the outer cable from the other handbrake operating arm.
6. Position the hand brake cable clear of the caliper. Push back the lock tabs (4), securing the hand brake caliper mounting bolts.
7. Remove the two mounting bolts, tab washer and retraction plate.
8. Slide the hand brake caliper around the brake disc, and withdraw through the gap exposed by the removal of the tie-plate.
9. Remove the brake pad securing clips, retaining pins, anti-rattle springs and brake pads from the caliper.
10. Loosen the caliper feed pipe union at the three way connector and disconnect the feed pipe from the caliper. Plug the ports to prevent loss of fluid and ingress of dirt.
11. Break the locking wire and remove the caliper mounting bolts.

CAUTION: Do not under any circumstances remove or attempt to remove, the bolts securing the halves of the caliper together.

12. Slide the caliper around the brake disc and withdraw it through the gap exposed by the removal of the tie-plate.





13. Remove the hub carrier fulcrum shaft grease nipple (2) to prevent damaging the nipple.





14. Remove the locking wire securing the radius arm bolt (1) and remove the bolt.
15. Lever the radius arm from the spigot anchor on the body. Position a jack or support blocks, under the hub carrier assembly.
16. Remove the nuts and washers securing the rear dampers to the lower wishbone.





17. Drive out the damper mounting pin (1); recover the front damper spacer collar.
18. Loosen the clip (3) securing the drive shaft inner universal joint cover and slide the cover along the drive shaft clear of the joint.
19. Remove the nuts (4 Fig. 1) securing the drive shaft flange to the brake disc. Carefully separate the drive shaft flange from the brake disc; collect the camber angle shims located on the disc mounting bolts.

NOTE: Record the number and value of the camber shims.

20. Remove the brake disc from the mounting bolts.

NOTE: DO NOT disturb the shims mounted between the final drive flange and the brake disc.

Installation
1. Assemble disc on to the mounting bolts. Replace the camber angle shims. Install the drive shaft flange over the shims on to the mounting bolts. Tighten the nuts to secure the drive shaft flange to the brake disc.
2. Check the disc for run-out. Clamp a dial test indicator to the suspension unit crossmember, position the indicator button against the brake disc face and zero the dial. Run-out must not exceed 0,10 mm (0.004 in.).
3. Install the brake caliper and secure with the mounting bolts. Check that the brake disc is central in the caliper by measuring the gap between the caliper abutments and the disc faces. The gap on opposite sides of the disc may differ by up to 0,25 mm (0.010 in), but the gap between the upper abutment face and the disc, and the lower abutment face and the disc, on the same side must be equal.
4. To adjust, remove the caliper and disc, add or remove shims from between the axle unit output shaft flange and the brake disc. Make a note of the thickness of the shims added or removed. On completion of the centralization operation, add or withdraw camber shims to the same value as those used in the above adjustment operation; i.e., if a 2,15 mm (0.085 in.) shim was ADDED between the axle unit output flange and the brake disc, to centralize the disc, then REMOVE the same value of the shims from the camber angle shim pack, fitted between the brake disc and the drive shaft flange. If shims were removed to centralize the disc, then ADD the same value of shims to the camber angle shim pack. This ensures that the camber angle, prior to the renewal of the disc, is retained. Tighten the drive shaft flange bolts to 66.5 to 74.5 Nm (49.2 to 55.2 ft lb).
5. When the disc is central in the caliper, tighten the caliper mounting bolts to 66 to 74 Nm (48.8 to 54.7 ft lb).





6. Lock wire the caliper bolt heads.





7. Reposition the radius arm to the body spigot, refit the bolt, tighten to 81 to 99 Nm (59.9 to 73.2 ft lb) and renew the lock wire.

NOTE: Prior to fitting the radius arm, wire brush the spigot and smear with grease.


8. Slide the universal joint cover into place, fit and tighten the securing clip.
9. Set up the handbrake caliper by holding the lever/carrier in one hand, and de-adjust (unwind) the remaining carrier, until the distance between pad faces is approximately 19 mm (3/4 in).
10. Install the handbrake caliper to the mounting position. Fit the retractor plate and a new tab washer, fit and tighten the securing bolts. Lock over the tabs.
11. Install and tighten the brake feed pipe.Ensure that the T piece union is tight.
12. Install the brake pads, retaining pins, anti-rattle springs (if fitted) and securing clips.
13. Install the hand- brake cable into the levers and refit the return spring. Refit the rubber boot over the cable. Operate the handbrake actuating lever until the adjuster ratchet ceases to click. The pads are now adjusted to the correct clearance.
14. Install the suspension tie plate, tighten to 22 to 27 Nm (16.3 to 20.0 ft lb).
15. Adjust the handbrake cable in the car so that with the handbrake fully OFF, there is a small amount of slack in the cable.

NOTE: If the cable is adjusted so that all the slack is removed, binding of the handbrake caliper may result.





16. Tighten the cable adjuster/locknut (1) to 19 to 24 Nm (14 to 17 ft lb), and refit the sill carpet.
17. Top up the reservoir (to the base of the filler neck) with NEW brake fluid from a sealed container.
18. Bleed the brakes. Service and Repair