Pad replacement
Caliper repair is basically carried out in the same way as described above. The operations for removing and installing brake pads are as follows:
1. Remove the upper and lower pad springs from the caliper (pic. A:11).
2. Remove the top and bottom guide bolts securing the caliper body to the bracket and remove the caliper body (pic. A:12) If the bolts have a slotted head, you will need a special 8mm 12-point slotted wrench.
3. Hang the caliper body on a wire hook without pulling on the brake hose.
4. Remove the brake pads from the caliper bracket.
5. Push the piston into the cylinder on the caliper body. Pay attention to the fluid level in the reservoir of the master cylinder (see above).
6. Install the brake pads into the caliper bracket and make sure they move freely in the bracket cavity.
7. Install the caliper body on the bracket and screw in the upper and lower guide bolts, tightening them to the torque specified in section "Technical data".
8. Install the upper and lower shoe springs (pic. A:11).
9. Replace all four brake pads on both brakes, then depress the brake pedal a few times to set the brake pads into position. Install the wheels and tighten the bolts to the torque specified in section "Technical data".
Removal and installation (Caliper VW Mk II)
Removing the brake caliper is a two step process. First, the caliper housing with the piston is removed, as described in the section "Replacement of brake pads", and then the caliper bracket.
After removing the caliper body, access is opened for repairing the caliper itself, the brake disc and the hub. Removal of the caliper bracket is required only in case of work on the steering knuckle (e.g. wheel bearing replacement).
If the caliper is to be repaired, depress 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 fitting from the caliper (instead of a clamp, you can use a clamp). Cap the disconnected end of the hose to prevent dirt from entering. After assembling the caliper, bleed the brake system as described above.
The spring washers mounted on the caliper bracket mounting bolts can be discarded - installation is not required during assembly. Tighten two bolts of fastening of a support to a rotary fist with the moment specified in the section "Technical data".
Replacement of seals (caliper VW MK II)
1. Remove the caliper body from the bracket as previously described. Remove the piston from the cylinder by applying compressed air to the brake hose fitting and remove the dust cover from the top of the piston.
2. Remove the O-ring from the groove in the cylinder with a plastic needle, taking care not to damage the surface of the cylinder bore.
3. Wash the piston and cylinder in methanol or clean brake fluid. Do not use gasoline or kerosene for flushing.
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 a new O-ring into the groove in the cylinder bore.
7. Install a new dust cover on top of the piston.
8. Insert the piston into the cylinder bottom first, then fully press it into place.
9. Install the outer edge of the dust cover into the groove along the top edge of the cylinder.
Visitor comments