Fitting 5 stud Vectra Rear Discs and Hubs to MK3 Astra/Cavalier

[v6-conv]

Vectra rear discs are 286mm (260mm on Cavalier/Astra) and run bigger pads, so look better and brake better too.

There are 2 methods of fitting Vectra rear discs

1) Redrill the Vectra back plate and fit it on the opposite side from it's donor, this reverts the Handbrake mechanism to the top, where as the Vectra is at the bottom and can't be used.

2) Make a hybrid setup with Original back plate, Vectra disc, hub and dust shield, and Omega calipers.

Parts required:

Option 1

Vectra 5 stud (2.0 &>) complete rear Stub axles (Disc, hub, back plate, pads and Calipers optional)

Note: The spacing of the pad retaining pins is different between Cavalier and Vectra Calipers, and Vectra calipers have the brake pipe connection at the bottom.

Option 2

Vectra 5 stud (2.0 &>) discs, dustshield, pads and hubs (only for 4 stud conversion).

Omega rear calipers (40mm).

If converting a non Disc model, back plate from a disc model.



How To

Jack up the car and support with axle stands

http://www.c-vox.com/howtos/5studrear/VectraRearDiscs%20000.jpg

http://www.c-vox.com/howtos/5studrear/VectraRearDiscs%20001.jpg

Remove the wheels, remove the handbrake cables and unplug the ABS sensor (where fitted)

http://www.c-vox.com/howtos/5studrear/VectraRearDiscs%20002.jpg

Unbolt and support the calipers

http://www.c-vox.com/howtos/5studrear/VectraRearDiscs%20003.jpg

Unbolt the Stub axle and remove it.

http://www.c-vox.com/howtos/5studrear/VectraRearDiscs%20004.jpg

This is where the different options come in
Option 1

The Vectra Back plate must be redrilled, to allow it to be fitted with the Handbrake mechanism at the top.

Ideally the handbrake slot wants to slope down towards the front of the car (away from the calliper). This will give more clearance for the Lower calliper bolt as you will see later.

NB: the opposite back plate makes an ideal template for redrillling.


http://www.c-vox.com/howtos/5studrear/RedrilledBackplate.JPG

Here are the redrilled Option 1 and Hybrid Option 2.

Note the angle of the handbrake mechanism on the Cavalier back plate on the right.

Notice the angle you can see the Vectra back plate is horizontal.

http://www.c-vox.com/howtos/5studrear/RedrilledVec-HybridCav.JPG

Here with the Stub axles fitted, and Vectra Calliper in place, you can see how close the lower bolt is, to the Beam.

This made it practically impossible to do up the bolt. Sloping the handbrake mechanism down at the front would rotate the calliper round and give enough clearance to get a ring or ratchet spanner on the bolt, still a socket won't go on.

http://www.c-vox.com/howtos/5studrear/VectraCaliperFitted.JPG

Here the finished Vectra Assembly - Option 1

http://www.c-vox.com/howtos/5studrear/Option1Complete.JPG

This redrilled backplate uses 2 of the existing holes, and works much better

http://www.c-vox.com/howtos/5studrear/RedrilledBackplate2.JPG

Option 2

Separate the dust shields from Original, and Vectra back plates (hammer and chisel all round)

http://www.c-vox.com/howtos/5studrear/VectraRearDiscs%20007.jpg

Fit the Vectra 5 stud hub, Dustshield and Vectra disc to the original back plate, then refit to the car.

http://www.c-vox.com/howtos/5studrear/VectraRearDiscs%20008.jpg

You have a choice of pads to use. Original 260mm Cavalier/Astra, Vectra 286mm, or Omega.

Here are pictures of the disc coverage with each pad (shame none go to the edge)

http://www.c-vox.com/howtos/5studrear/VectraRearDiscs%20009.jpg

http://www.c-vox.com/howtos/5studrear/VectraRearDiscs%20010.jpg

http://www.c-vox.com/howtos/5studrear/VectraRearDiscs%20011.jpg

Over to the Omega Calipers, they need a couple of mm fettling off in the disc area

http://www.c-vox.com/howtos/5studrear/VectraRearDiscs%20013.jpg

Here fully assembled.

http://www.c-vox.com/howtos/5studrear/VectraRearDiscs%20015.jpg

Comparing the 260mm Cavalier and 286mm Vectra parts.

http://www.c-vox.com/howtos/5studrear/VectraRearDiscs%20016.jpg

The other side fitted

http://www.c-vox.com/howtos/5studrear/VectraRearDiscs%20017.jpg