Contents: Replacing the pads ↓ Removal and installation (VW Mk II…↓ Replacing seals (VW MK II caliper) ↓
Replacing the pads
Repair of the caliper is basically carried out in the same way as described above. The operations of removing and installing the brake pads are carried out as follows:
1. Remove the upper and lower brake pad springs from the caliper (figure O:11).
2. Remove the upper and lower guide bolts securing the caliper body to the bracket and remove the caliper body (drawing O:12) If the bolts have a slotted head, you will need a special 12-sided slotted wrench measuring 8 mm.
3. Hang the caliper body on the wire hook without stretching the brake hose.
4. Remove the brake pads from the caliper bracket.
5. Press the piston into the cylinder on the caliper body. Note the fluid level in the master cylinder reservoir (see above).
6. Install the brake pads into the caliper bracket and make sure that they move freely in the bracket cavity.
7. Install the caliper body onto the bracket and install the upper and lower guide bolts, tightening them to the torque specified in Section "Technical data".
8. Install the upper and lower brake shoe springs (figure O:11).
9. Replace all four brake pads on both brakes, then press the brake pedal several times to set the brake pads in the operating position. Install the wheels and tighten the bolts to the torque specified in the section "Technical data".
Removal and installation (VW Mk II caliper)
Removing the brake caliper is done in two stages. First, remove the caliper body with the piston, as described in the section "Replacing brake pads", and then the caliper bracket.
After removing the caliper housing, access is opened for repairing the caliper itself, the brake disc and the hub. Removing the caliper bracket is only required in case of work on the steering knuckle (for example, replacing wheel bearings).
If the caliper is to be repaired, press the brake pedal to push the piston out of the cylinder and make it easier to remove later.
If it is necessary to remove the caliper body completely, clamp the brake hose with a special clamp and unscrew its nipple from the caliper (instead of a clamp, you can use a clamp). Plug the disconnected end of the hose to prevent dirt from getting in. After assembling the caliper, bleed the brake system as described above.
The spring washers installed on the caliper bracket mounting bolts can be discarded - they do not need to be installed during assembly. Tighten the two caliper-to-steering knuckle mounting bolts to the torque specified in the section "Technical data".
Replacing seals (VW MK II caliper)
1. Remove the caliper body from the bracket as described earlier. Remove the piston from the cylinder by applying compressed air to the hole for the brake hose nipple and remove the dust boot from the top of the piston.
2. Remove the sealing ring from the groove in the cylinder using a plastic needle, being careful not to damage the surface of the cylinder bore.
3. Wash the piston and cylinder in methyl alcohol or clean brake fluid. Do not use gasoline or kerosene for washing.
4. If the piston and cylinder are in good condition, assemble the caliper body as follows:
5. Lubricate the piston, O-ring and cylinder with clean brake fluid.
6. Install the new O-ring into the groove in the cylinder bore.
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7. Install a new dust boot onto the top of the piston.
8. Insert the piston into the cylinder, bottom first, then press it all the way into place.
9. Install the outer edge of the dust boot into the groove along the top edge of the cylinder.
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