1973 OPEL GT-R brake fluid

5B- 141973 OPEL SERVICE MANUALConditionPossible CauseCorrection2. Partial system failure.2. Check front and rear brake system
and repair, if necessary. Also, check
brake warning light, if a failed
system is found and light did not
function.
3. Excessively worn shoe
and lining.3. Check and replace in axle sets.
4. Piston in caliper stuck
or sluggish.4. Remove caliper and rebuild.
5. Fading brakes due to
incorrect lining.
6. Vacuum leak.5. Remove and replace with original
equipment lining.
6. Check for ruptured hose or loose
attachment.
Excessive Pedal Travel1. Partial brake system
failure.1. Check both front and rear system
for a failure and repair. Also, check
warning light
- it should have indi-
cated a failure.
2. Insufficient fluid in
master cylinder.
3. Poor rear brake
adjustment.2. Fill reservoirs with approved
brake fluid. Check for leaks.
3. Adjust rear brake per
specifications.
4. Air trapped in system.4. Bleed system.
5. Bent shoe and lining.5. Replace axle set of shoe and
lining.
Dragging Brakes (A very
light drag is present in
all disc brakes
immediately after pedal
is released.)1. Master cylinder pistons
not returning correctly.1. With reservoir cover off, check
for fluid spurt at bypass holes as
pedal is depressed. Adjust push rod,
if necessary, or rebuild master
cylinder.
2. Restricted brake tubes2. Check for soft hoses or damaged
or hoses.tubes and replace with new hoses and
new double-walled steel brake tubing.
3. Incorrect parking brake
adjustment on rear brakes.3. Check and readjust to correct
specifications.
Grabbing or Uneven Braking
Action (All conditions
listed under “Pulls”
.)4. Check valve installed in
outlet to front disc brakes.
1. Malfunction of power
brake unit.4. Check master cylinder outlet and
remove check valve if present.
1. Check operation and repair, if
necessary.

DISC BRAKES5B- 15
ConditionPossible Cause
2. Binding brake pedal
mechanism.Correction
2. Check and lubricate, ifnecessary.3. Corroded caliper
assembly.3. Clean and lubricate.
MAINTENANCE AND ADJUSTMENTSDISC BRAKE MAINTENANCE
Checking Brake Fluid Level
The brake fluid level in the brake fluid container
must be checked during predelivery inspection, then
every 3,000 miles during inspection and preventive
maintenance servicing.
The brake fluid level must not be higher than the
inscription “MAX” and must be at least up to
“MIN”. Replenish brake fluid, if necessary.
Because of the relatively large brake caliper bore
cross section and the self-adjustment of the disc
brakes, resulting in a greater piston travel to compen-
sate for friction pad wear, the brake fluid level drops
faster than in fluid containers for drum brakes with
their smaller wheel brake cylinders. For this reason
pay special attention to the fluid level in the brake
fluid container.
Drop of brake fluid level can be due to friction pad
wear and may not be due to leakage in the braking
system.On loss of brake fluid due to leakage, the brake sys-
tem must be checked thoroughly.
Friction Pad Adjustment
Friction pad adjustment is not necessary on the front
wheel disc brakes as this is done automatically by the
pistons in the brake calipers.
Lubricating Front Wheel Bearings
When removing one or both brake discs, check lu-
brication of front wheel bearings and the cavity of
the wheel hub and replenish if necessary (see operat-
ion
“Removing and Reinstalling Brake Disc”).
When carrying out other work on disc brakes which
does not necessitate the removal and installation of
the brake disc, lubricating wheel bearings is not
necessary.Checking Disc Brake Friction Pads for Wear
Whenever a disc brake equipped car is in for periodic
service, while the car is raised, the friction pads in
both brake calipers should be checked for wear by
making a simple measurement. Worn or oily friction
pads must be replaced.
Measure friction pad wear as follows:
1. Remove friction pads.
2. Using a one-inch micrometer, measure the thick-
ness of the pad and friction plate. See Figure
5B-23.Figure 58-23 Checking Brake Friction Pad Thickness
3. If any one of the four measurements is less than
-.280, replace all four friction pads. (Partial replace-
ment of friction pads would cause unequal braking.)
Removal and Installation of Friction Pads
1. Raise car and remove front wheels.
2. Drive dowel pins out of brake calipers toward
center of car. See Figure
5B-24. Dowel pins must be
driven inward because they are secured by enlarge
fluted inner ends.
3. Remove friction pads from brake calipers. See
Figure
5B-25.

5B- 19i973 OPEL SERVICE MANUAL
Figure
56-24 Removing Dowel Pins
Figure 56-25 Removing Friction Pads
4. Check rubber seals for wear. If rubber seals are
hardened, brittle or cracked, they must be replaced
as follows:
(a) Remove brake caliper from steering knuckle and
brake disc. Leave hose attached to brake caliper.
(b) Remove seal clamp rings with screwdriver and
remove seal rings from calipers. See Figure
5B-26.(c) Install new rubber seals and clamp rings. Make
sure rubber seal is properly seated. Make sure clamp
ring is correctly positioned on rubber seal,Figure 56-26 Removing or Installing Rubber Seal
Clamp Ring
(d) Attach brake caliper to steering knuckle and
torque bolts to 72
Ib.ft. Prior to installation of
caliper, make sure contacting surfaces of both caliper
and steering knuckle are perfectly clean and free of
any burrs.
CAUTION: This disc brake caliper attachments fas-
tener is an important attaching part in that it could
affect the performance of vital components and sys-
tems, and/or could
result in major repair expense. It
must be replaced with one of the same part number
or with an equivalent part, if replacement
becomes
necessary. Do not use a replacement part of lesser
quality or substitute design. Torque values must be
used as specified during reassembly to assure proper
retention of this part.5. Before installing new friction pads, press both pis-
tons of each caliper to bottom of their bores, using
Return Clamp J-22430.
While pressing piston into
bores, open caliper bleeder valve to prevent excess
brake fluid from overflowing master cylinder con-tainer As soon as pistons are bottomed, tighten
bleeder valve.
6. Check brake disc for lateral runout.
7. Install new friction pads into brake caliper. Fric-
tion pads must be free enough to be easily moved in
their caliper recesses. See
Figure X3-25.If new friction pads are not free, it will be necessary
to remove pads and clean recesses and recess corners
with a wooden spatula and then with denatured al-
cohol and a brush. After cleaning, blow out recesses
with compressed air. Remove any high spots on
edges of friction pads contacting caliper recesses with

DISC BRAKES58.17a tine cut file.Do not use any solvent except dena-
tured alcohol. Do not use a
metaIJic scraper too/.8. With a punch, drive one dowel pin from inboard
side through caliper and friction pads to stop. Install
new cross-shaped retaining spring under installed
dowel pin, then install second dowel pin. Loose tit-
ting dowel pins must be replaced.
9. Before operating vehicle, depress brake pedal sev-
eral times to adjust friction pads to brake discs.
Check brake fluid level and add fluid as necessary to
bring level up to “MAX” on reservoir.
Car owners must be informed that a break-in period
exists for new friction pads, and that they must avoid
unnecessary, forceful braking during the first 125
miles after installation of new friction pads.
Checking Brake Disc for Lateral Runout1. Remove front wheel assembly.
2. Remove front wheel bearing hub cap and spindle
nut cotter pin. Tighten spindle nut until all free play
is removed from wheel bearings.
3. To check disc runout, use Dial Indicator Set
J-
8001. Attach dial support C-clamp to an upper ball
joint attaching bolt as shown in Figure
5B-27. Posi-
tion dial indicator button against brake disc
l/2 inch
from outer circumference.
Figure 58-27 Checking Brake Disc Lateral
Runout4. Rotate disc, reading maximum dial indicator
movement. Maximum permissible runout is
,004
inch.5. If runout exceeds
0% inch, remove disc and hubassembly and true disc in a suitable disc turning
lathe, following manufacturer’s instructions. The
depth of cut on each side of disc should be just deep
enough to get a true flat surface.
6. After truing disc on both sides, check thickness
with a micrometer. A disc with a thickness of less
than ,394 inch is liable to warp after hard braking
and, therefore, must be discarded.
7. Reinstall brake disc and hub assembly, removing
all play from wheel bearings. Repeat runout check.
If runout still exceeds
,001 inch, replace brake disc.
8. Adjust front wheel bearings.
9. Reinstall front wheel assembly.
MAJOR REPAIR
REMOVING AND INSTALLING BRAKE CALIPER1. Remove left or right front wheel and remove fric-
tion pads from brake caliper.
2. Loosen brake line to brake caliper union nut sev-
eral turns. Unscrew brake caliper plus brake hose
bracket from steering knuckle. Remove it from brake
disc and swing it sideways. Then unscrew brake pipe
from brake hose and remove brake caliper and brake
pipe (bent pipe). To prevent brake fluid loss, close
brake hose with a plug.
3. Prior to installation,check contacting surfaces of
the brake caliper and steering knuckle to make sure
they are free of any burrs and dirt.
4. Install brake caliper on steering knuckle and
torque attaching bolts to 72
lb.ft. See Figure 5B-28.CAUTION: This disc brake
cah@er attachments fas-
tener is an important attaching part in that it could
affect the performance of vital components and sys-
tems, a,ld/or could result in major repair expense. It
must be replaced with one of the same part numberor with an equivafent part, if repfacement becomes
necessary. Do not use a replacement part of Jesser
quaJity ‘or substitute design. Torque vafues must be
used as specitied during reassembly to assure proper
retention of this part.
5. Attach brake pipe to brake hose.
6. Install friction pads and replace wheel.
REMOVING AND INSTALLING
BRAKE DISC
1. Jack-up and support front of car and remove front

58.201973 OPEL SERVICE MANUAL
half, and blow out pistons, carefully regulating air
flow. When removing pistons, proceed with extreme
caution and always keep the fingers ofthe hand hold-
ing the brake caliper away from the piston.
Figure 55.33 Removing Caliper Rim Half Piston
Figure 58-34 Removing Caliper Mounting Half Piston
4. Pry rubber fluid seals out of the annular grooves
in the caliper half bores. See Figure
5B-35.5. Check all parts of the brake caliper for wear. If the
caliper half bores are scored or rusted, use a new
complete brake caliper and friction pads. Small, light
rust spots in the caliper half bores or on the pistons
can be removed with fine emery cloth. If pistons are
damaged, even though the caliper half bores are inFigure 58-35 Removing Rubber Fluid Seal From
Caliper Boresgood condition, the piston must be replaced. The
rubber fluid seals and rubber seals with
clapp rings
for the pistons are to be replaced every time repair
work is carried out on the brake caliper.
6. Thoroughly clean all reusable parts
- complete
brake caliper and pistons
- with denatured alcohol
and dry with compressed air. Prior to cleaning, screw
bleeder valve out of caliper.
7. Lightly coat new rubber fluid seals with brake
fluid and insert fluid seals into grooves of brake
caliper bores.
8. Place brake caliper into vise to install pistons.
After installing one piston, change position of brake
caliper in vise to install second piston. The piston to
friction pad spacer plates should be used as a gauge
to locate relieved edge of piston at 20 degrees to
horizontal during piston installation. See Steps
9-IO-
11-12.9. Place caliper mounting half in vise and coat its
bore and piston lightly with brake fluid. Then push
piston, with hollow end towards brake disc, into the
caliper bore. Turn piston so that the relieved edge
faces downwards at an angle of 20 degrees and facing
in brake disc direction. The guide surface in the
caliper half recess at the brake pipe connection side,
will properly align the piston. Push piston into
caliper bore up to the stop.
10. Change position of brake caliper and install sec-
ond piston in the same manner.
11. Install new rubber seals with clamp rings. Make
sure that the rubber seals are properly seated on the

DRUM BRAKES5C- 23
Parking Brake Control System
The hand-operated parking brake lever is mounted
between the front seats on the propeller shaft tunnel.
A paw1 is riveted into the parking brake lever and is
actuated by a control rod provided with a spring
loaded push button. When the parking brake is ap-
plied, the parking brake lever is locked by the
paw1which engages the teeth on a stop plate. The parking
brake is disengaged by pressing the spring loaded
push button. See Figure
5C-41.
SPRING LOADED,-PUSH BUTTON
BRAKE LEVER
s\., \\,Figure
5C-4 1 Parking Brake Lever (Opel 1900 and
Manta)The GT arrangement of the parking brake is, with
the exception of the additional transmittal lever at
the floor panel, identical with that of the Opel mod-
els. The transmittal lever is attached to the propshaft
tunnel by means of a mounting support. See Figure
5C-42.The parking brake lever is connected with the front
parking brake pull rod. By means of an equalizer, the
front pull rod is connected to the forward portion of
a center cable. The center cable is routed rearward
through retaining guides and attaches at either end
to the lower end of a parking brake lever. See Figure
5C-43. The parking brake levers and struts actuate
the rear wheel brakes.
Service Brake Control System
-Standard Brakes
The service brake control system is a pedal operated
hydraulic system which applies the brakes at all four
wheels with equal pedal pressure. The hydraulic sys-
tem consists of a master cylinder (and attached trans-
parent fluid reservoir) connected by pipes and
1.PUSH BUTTON
2.THRUST SPRING
3.WASHER
4. PAWL CONTRO ROD
5. PARKING BRAKE LEVER
6.RIVET
7. HEX. HEAD BOLT
8.TOOTHED SEGMENT
9. PAWL WITH TWO TEETH
10.RUBBER CAP
11.THRUST ROD
12.PULL ROD
13.TRANSMITTAL LEVER
14.MOUNTING SUPPORT
15.BOLT
16. PARKING BRAKE CABLE
17. RETURN SPRING
sea2Figure 5C-42 Parking Brake Lever
(GT)flexible hoses to a wheel cylinder mounted between
the brake shoes at each rear wheel.
A mechanically-operated stop light switch is
mounted on a bracket just forward of the brake pedal
on the GT and just rearward of the brake pedal on
the Opel 1900 and Manta. With brake pedal released,
the switch plunger is fully depressed against the
switch actuating lever. See Figures
5C-45 and 5C-46.Any time the stop light switch fails, the stop lights
will stay on at all times.

DRUM BRAKES5C- 25PISTONCYLINDER HOUSING
BLEEDER VALVE
SC-47Figure
5C-47 Wheel Cylinder Exploded View
cups are of a special heat resisting rubber. Theagainst the ends of the shoes. Rubber boots en-
inlet port for brake fluid is located between theclose both ends of the cylinder to exclude foreign
pistons so that when fluid pressure is applied,
matter. A valve for bleeding brake pipes and
both pistons move outward in the wheel cylin-wheel cylinder is located in the back of the cylin-
ders. The pistons impart movement to the brake
der casting and extends through the brake backing
shoes of the rear wheel brakes by bearing directly
plate assembly. See Figure 5C47.

DRUM BRAKES5C- 27MAINTENANCE AND ADJUSTMENTSBRAKE ADJUSTMENT
Preliminary Checks
1. Depress brake pedal firmly. If pedal travels to
within two inches of toeboard and has a hard feel,
brake shoes require adjustment or relining. However,
if pedal has a spongy feel, brake system needs bleed-
ing.2. Remove one rear drum if lining is worn nearly to
rivets. Reline both rear brakes (drum brakes only).
3. Check fluid level in master cylinder reservoir and
add fluid if necessary.
4. Fully release parking brake lever and place trans-
mission in neutral.
5. Pull on both ends of rear brake cable a number of
times to make sure that cables operate rear brake
shoes freely and do not bind in conduits. Check for
free movement of cable in brake cable sheave and
check brake cable spring for tension. Replace a weak
or broken cable spring.
Pedal Height Adjustment
Brake pedal height can be adjusted by first removing
the nut and lock tab from the brake pedal to clevis
attaching bolt and then by turning the head of the
bolt and rotating the eccentric until there is approxi-
mately
l/4 of an inch play in the brake pedal. See
Figures
X-49 and 5C-50. Replace lock tap and nut.
If one of the tabs on lock tap breaks replace lock tab.5c49
Figure 5C-49 Brake Pedal Attaching Bolt and
EccentricFigure 5C-50 Brake Pedal Height Adjustment
If binding does occur, take pedal assembly apart and
clean. Check for broken parts. Lubricate and replace.
Adjustment at Wheels
At each rear wheel brake assembly there are two (2)
brake shoes, and each brake shoe has an individual
adjustment eccentric. Therefore, each shoe must be
adjusted separately by turning its adjustment
ccccn-tric which is mounted on the brake backing plate.
Arrows on backing plate circumference show direc-
tion in which eccentrics should be turned to get
brake shoe-to-drum contact. See Figure X-51.
When adjusting front brake shoe ofrear brakes, turn
wheel forward. When adjusting rear brake shoe of
rear wheel brakes, turn wheel rearward. Adjust as
folio ws:1. Raise car and support in a safe manner so that all
wheels clear ground. Prior to wheel brake adjust-
ment, check that all brake drums rotate freely.
2. Revolve drum in forward direction and turn front
brake shoe eccentric in direction of arrow until brake
shoe contacts brake drum. See Figure
5C-49, then
turn eccentric in opposite direction until brake drum
is just free to turn. Adjust rear brake shoe in the same
way but revolve brake drum in backward direction.
3. Remove car jacking and support equipment, and
road test car for brake performance.
Disc brakes do not require adjustment.
Parking Brake Adjustment
Adjustment of parking brake cable is necessary
whenever the rear brake cables have been