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2.0 CDTI excess play in caliper

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5.8K views 11 replies 5 participants last post by  Hoodjoe004  
#1 ·
We have a 2011 Astra SRi 2.0 CDTI with some kind of exterior pack (19" wheels).

We purchased the car when it was around 9 month old, around a year into ownership a knock/rattle started to develop on the driver of the car. After numerous visits to Vauxhall they changed the shocks and a number of other things, until finally I pointed out that the noise was coming from the calliper which you could physically move with your hand.

It's probably common knowledge on here, but there seems to be an issue with excess play in the callipers on some models. Vauxhalls answer to the problem is the pack the caliper pins with grease and tighten the pins onto the carrier in a way which restricts the play. We had this done by vauxhall which resolved the problem for a few month.

The car was out of warranty and we took it to a local garage to have it's pads changed, thats when the noise returned. No matter what we do we are unable to get rid of this noise. We've had the pins re-greased twice since.

In January the car needed an MOT and service, so I purchases a calliper from someone on ebay. The calliper came from a 2014 car and looked almost brand new (no rust). We got this fitted, along with new discs and new pads. Finally, the noise was gone, the car was lovely to drive, what a difference.... until two week later when the noise came back. So I've had the car in the garage again to have the pins greased. No difference.

The noise itself, if anyone has experienced it make the car sound like a knackered old taxi when you go over bumps. It's horrible. I suspect that because our car is fitted with 19" wheels, then this caused the calliper to work lose somehow, it's surely the only way to explain whey the noise re-appeared even with another calliper. What I can't explain though, is why the passenger side has NEVER experienced this issue.

Im guessing others must have had this issue and I wondered how others had fixed this?

Does anyone sell aftermarket callipers for the Vauxhall Astra? I'm guessing a new calliper make by someone other than vauxhall might help.
 
#3 · (Edited)
I can't say I've heard of anything like that. I don't see how the wheels can be causing the issue.
There are brake upgrades that mean changing callipers but that isn't a cheap option
There's a vauxhall technical bulletin(2857 08/11/11 Disc Brakes - Rattle Noises ASTRA -J) for customers complaining on knocking/rattling noises over uneven surfaces. It can happen to both the front and rear brakes, but on the rear they also apply 3M double sided tape to the pads to stop them moving around. From the research I've done, it seems it's also a problem on some Chevrolet models (maybe they use the same caliper)?

The reason I think the wheels could be causing the issue is that the 19's have lower profile tyres which as a result transfers more of the bumps on the surface of the road to the car, this I think could be causing the calliper pins to work lose in the holes, but also I think it probably makes the noise sound worse than it would be on say smaller wheels with bigger tyres (the tyres themselves would absorb more vibrations).

Can you tell me what upgrade options are available? I'm at the end of my tether with this rattling noise.
 
#6 ·
I've covered this problem many times on here...

A primary cause is the slide pin with the rubber sleeve on - replace them with a solid pin.
The root cause is the poor tolerances of this cheap caliper - the slide pins are a very loose fit.

Sheep, have a read of my contributions in these threads.
The last thread is where I detailed the mods I did, though sorry the photos are no longer on imageshack. If anyone wants them I can upload them?

http://www.astraownersnetwork.co.uk/showthread.php?246225-Rattle-from-suspension&p=4502257#post4502257

http://www.astraownersnetwork.co.uk/showthread.php?130675-Vauxhall-parts-brake-pads&highlight=astra+brake+rattle

http://www.astraownersnetwork.co.uk/showthread.php?159537-astra-j-rear-rattles/page2&highlight=astra+brake+rattle

http://www.astraownersnetwork.co.uk/showthread.php?193522-Knock/page2&highlight=astra+brake+caliper

http://www.astraownersnetwork.co.uk...r-anti-rattle-mods-(with-photos)&highlight=Astra+rear+calliper+anti-rattle+mods
 
#7 ·
r44flyer

Thank you. I'll order a new set of pins and give it a try.

You know, I did re-grease them myself once, and the rubber on one of the pins did concern me a little and I considered replacing it with a solid one, even if only because I couldn't get the bloody pin with the rubber back in the hole.
 
#12 ·
Hope this works as I’ve had a nightmare with my Astra what a money pit then this rattle av had shock absorbers replaced, mounts, bearings all sorts and still my car sounds like A tank over pot holes etc what a noise people about they nearly snap there neck to see what that horrible noise is ,only to realise that when I was braking the noise did not happen n here I am I understand that the noise may go for a while but what is permanent fix ?? If non it needs sold ASAP can’t take the noise anymore