Cav GSi handbrake query

[Calibre500]

Hi. I'm slowly trying to get bits sorted on my GSi that's been parked up for 15+ years and the handbrake is next. I have forgotten how it connects to the rear hubs as I dismantled it a long time ago but am looking to buy a new one in case the existing one is totally buggered. I've seen these 2 which I think are BorgNBeck but for the Calibra. I'm assuming they will be the same as a Cav GSi??
Anyway I can find out if these item numbers are suitable? LH & RH - BB12220B BB12221B; Calibra 4x4 Turbo Handbrake Cable BB12234B - Cavalier 2.0 16v.

Thanks

[Robsey]

I have looked at the part number 90 374 902.

It is the same part for the Calibra and the Cavalier with independent rear suspension. - GSi, 4x4 and Turbo.

Calibra -
Item 1

http://www.catcar.info/opel/?lang=en&l= ... 0xNQ%3D%3D

Cavalier 4x4, GSi etc
Item 14

http://www.catcar.info/opel/?lang=en&l= ... eT09MjU%3D

[Calibre500]

Thank you Robsey. Do you know if the cable is 2 separate cables (left and right) or 1 cable split into 2 sides?? Thanks.

[iangsi]

The cable can be broken down into 3 parts a single cable to the lever which goes back to a yolk type assembly which is fixed to the tunnel on the passenger side then the left & right side cables.

[Robsey]

As Ian suggests,

It is two separate cables and an equalizer bar.

But I notice that the part number appears to identify the two cables together.

[Calibre500]

I've tried to do a search for removing the handbrake cable but I can't find anything. Is there a 'How to' on the forum?? I've tried looking under GSi/Turbo/4x4. Thanks.

[Calibre500]

Hi. Can anyone help re 'how to' for removal of GSi handbrake cables as mentioned above?? Thanks

[Robsey]

I have looked for ages trying to find threads on the GSi rear brake set-up.

Looked at the various Calibra threads, but no difinitive thread on removal and fitting of new cables.

So in the absence of any documents...
(This is where a Haynes manual for a Calibra could be useful).
The Cavalier manual also covers this on rear disc brakes for DOHC engines.
(Double overhead cam / 16 valve engines).

From what I can see.
It looks like the rear cables and equalizer bracket (yoke) all come as an assembly.

So - and this is by pure guess work.

Jack up and support the rear of the car on sturdy axle stands.

Remove the rear wheels.

Get underneath.

If you have a catalytic converter, you will need to unbolt the heat shield to access the equalizer bracket.
This is held on by four nuts.

Slide the heat shield rearwards and around the exhaust middle box.

Looking at the cable equalizer yolk -
give the threaded bar of the cable from the handbrake lever a liberal spraying with plus-gas, wd40 or other release agent and allow to penetrate.

Loosen and unscrew the nut on the threaded cable to allow the yolk to be removed.

Moving to the rear disk / drums.
Remove the single screw holding the disc on, and carefully tap the disk / drum from the hub.

Once inside, unhook the handbrake cables from the hook on the operating lever.

Now is a good time to clean everything up, and check on the condition of the back plate.
(These rot out badly on calibras, so may be just as poor on the Cavalier IRS set-up).

Reassembly...

If fitting new shoes, then wind in the self adjuster.

Hook the cable over the operating lever hook.

Route the cable towards the front of the car, using the same root as the old cables.

Attach the yoke to the front hand-brake cable threaded bar and adjust to a similar position that the old set-up occupied.

Refit the rear disk / drums, and adjust the cable tightness via the self adjuster mechanism.

Adjustment...

Go into the car and pull the handbrake lever until it's ratchet pawl clicks once.

Return to the rear wheels and adjust the shoes as follows.

Line up the inspection window on the disk / drum with the ratchet teeth on the self adjuster.
Insert a flat screw driver through the window and lever the ratchet wheel to tighten.


(Image taken from Club Calibra).

Spin the rear disk / drum to check operation.
And keep adjusting until you are satisfied.

A good baseline would be for the shoes to start rubbing with one click of the handbrake lever,
But to spin freely with the lever fully down.

Full lock should be achieved with approx 4 to 6 clicks of the handbrake lever.

You may have to keep checking one side (disk / drum) then the other and back again to ensure that the cables are adjusted so that the tension is balanced between both sides.

When happy - refit the disk / drum retaining screws.
Refit the wheels.
Refit the catalytic converter heat shield.
Lower the car back to the ground.
Torque up the wheel bolts...
and
Go for a drive to check for satisfactory operation.

[Calibre500]

Thank you SO MUCH Robsey.

I have looked but couldn't find anything anywhere. You'd have thought with how popular the GSi/Turbo Cavs are there'd be something on a forum or YouTube but nothing.

I have looked under the car earlier before it started raining and it needs disconnecting from one hub, the other is done. Have to leave till next weekend now so hope weather is dry then.

[Robsey]

edited as if by magic
(Actually Robert is my name, and it is Sunday afterall).

I love a challenge, hence why I had a good look round.

To be honest, Vauxhall's own technical info system gives a lot less info than Haynes.

You have email

[Calibre500]

Definitely magic lol. Is there a thing on this forum where you can give thanks to someone because I know you deserve it? I thought no one was going to reply hence trying a re-post again.

[Robsey]

Is there a thing on this forum where you can give thanks to someone?

You just did give thanks.

That is very kind of you,
and you are most welcome.

I hope everything makes sense.
It looks more complicated than it is.

Just take it a few lines at a time.
The important thing is safety.

Ensure you have good sturdy axle stands fitted in a secure position.
And put bricks or chocs in front of the front wheels for extra security.

[Calibre500]

I'll go over your 'how to' a few times before attempting it. I think only issue will be where the cable is fixed on the trailing arms as they look seized.
Car is already on 4 axle stands, (front/back).

[Robsey]

Plenty of plus-gas then on the cable mounts.
Allow it to soak in and do it's magic.

I think Haynes says you may need to bend some brackets a little to get the cables out and back in.

See page 142 of the pdf.

[Calibre500]

Hi Robsey. Yes the email has come through. I've yet to download it but can't see any issues.
Will download tomorrow and go through it with hope it's dry Sat/Sun so I can get under the car. Brilliant summer we're having. Not much for hot weather but should be dry at least.

[Robsey]

Good good.
Weather here is meant to be cool but dry, so hopefully we can all get some long overdue jobs done.

(Thread tidied up to remove excess conversation).