Opel Frontera UE. Manual - part 740

5C–30

POWER-ASSISTED BRAKE SYSTEM

Special Tools

ILLUSTRATION

TOOL NO.

TOOL NAME

5-8840-2300-0

(J-39216)

Push Rod Gauge

5-8840-0279-0

(J-23738-A)

Vacuum Pump

5-8840-2305-0

(J-39241)

Push Rod Support

POWER-ASSISTED BRAKE SYSTEM

5C–31

Front Disc Brake Pads

Front Disc Brake Pads Inspection

Check the outer pad by looking at each caliper from 
above. Check the thickness on the inner pad by looking 
down through the inspection hole in  the top of the 
caliper. Whenever the pad is worn to about the 
thickness of the pad base, the pad should be removed 
for further measurements. The pad should be replaced 
anytime the pad thickness (1) is worn to within 1.00 mm 
(0.039 in) of the pad itself.
The disc pads have a wear indicator that makes a noise 
when the pad  wears to where the replacement is 
required.

Minimum limit (1): 1.0 mm (0.039 in) 

302RS002

Front Disc Brake Pads and Associated Parts

302RW003

Legend

EndOFCallout

(1) Lock Bolt
(2) Caliper Assembly
(3) Pad Assembly

(4) Clip
(5) Outer Side

5C–32

POWER-ASSISTED BRAKE SYSTEM

Removal

NOTE:  If a squealing noise occurs from the front brake 
while driving, check the pad wear indicator plate. If the 
indicator plate contacts the rotor, the disc pad assembly 
should be replaced.

• Draw out two–thirds of the brake fluid from the 

reservoir.

• Raise the vehicle and support it with suitable safety 

stands.

1. Remove wheel and tire assembly, refer to “Wheels 

and Tires System" in Section 3E.

2. Remove lock bolt (1).

302RW004

3. Rotate caliper assembly and support the caliper 

assembly so that the brake hose is not stretched or 
damaged.

4. Remove pad assembly with shim.

5. Remove Clip.

Installation

1. Install clip.

302RS005

2. Apply special grease (approximately 0.2g) to both 

contacting  surfaces of the inner shims (2). Wipe off 
extruded grease after installing. Install pad 
assembly with shim.

302RW005

Legend

EndOFCallout

(2) Inner Shim
(3) Wear Indicator
(4) Inner Side

POWER-ASSISTED BRAKE SYSTEM

5C–33

302RW006

3. Use adjustable pliers to bottom the piston into the 

caliper bore. Be careful do not damage the piston 
boot and do not damage the flexible hose by twisting 
or pulling it.
Install caliper assembly. 
Set caliper assembly in place.

302RS008

4. Install lock bolt (5) and tighten the bolt to the 

specified torque.

Torque: 74 N·m (7.5 kg·m/54 lbft)

302RW018

5. Install wheel and tire assembly, refer to “Wheels and 

Tires System" in Section 3E.

6. Pump the brake pedal several times to make sure 

that the pedal is firm.  Check the brake fluid level in 
the reservoir after pumping the brakes.