Contents: Removal ↓ Installation ↓
Support C-38/C-II41
Attention! The brake mechanisms of the front wheels of Golf cars can be equipped with two types of calipers. It is recommended to use the illustrations to determine the type of caliper on the car being repaired.
Removal
Attention! Brake linings are classified as materials that require an operating permit and are included in the General Operating Permit Register (ABE). In addition, they are selected by the manufacturer for specific vehicle models. Therefore, it is recommended to use only the linings offered by the manufacturer.
Warning! Jacking up a vehicle may pose a risk of injury. It is recommended that you familiarize yourself with the safety precautions for installing a vehicle on jack stands.
1. Jack up the car and place it on jack stands.
2. Mark the direction of rotation of the wheel with an arrow on the sidewall of the tire and loosen the wheel bolts.
3. Jack up the rear of the car and remove the rear wheel.
Caution! If the brake pads are to be reinstalled for further use, they must be marked before removal. Switching the pads from the right wheel to the left and vice versa or switching the outer and inner pads is not allowed. Be sure to change all the brake pad linings on the front wheels, even if only one of them has reached the maximum permissible thickness.
4. Unscrew the caliper mounting bolts, holding the guide pins from turning (see illustration).
5. Remove the caliper from the brake shoe guide and secure it to the body with wire.
Caution! The caliper must be secured so that it does not sag and does not stretch or twist the connected brake hose with its weight.
6. Caliper C-38. Remove the brake pads.
7. Caliper C-II41. Remove the brake pads together with the pressure springs.
Installation
Caution! When the brake pads are removed, do not press the brake pedal. In this case, pressing the pedal will push the piston out of the brake cylinder.
8. Inspect the brake disc and make sure it is not damaged or worn. Clean the caliper only with alcohol.
The use of sharp objects or metal brushes for these purposes is not permitted.
9. Press in the brake cylinder piston using a special pressing tool 1 for rear disc brakes, e.g. HAZET 4970/6 (see illustration).
Caution! Pressing in the wheel cylinder piston with conventional tools is not permitted, as this will damage the parking brake adjusting device.
10. Screw the piston into the wheel cylinder by turning the handle of the special device clockwise. The projection 2 of the device should be adjacent to the caliper.
Make sure that the protective cap of the cylinder is not damaged. If the piston enters with difficulty, then when screwing in the piston, turn the rod of the device by the flats with a wrench.
Caution! When screwing in the piston, brake fluid is squeezed out of the wheel brake cylinder into the expansion tank. Monitor the brake fluid level in the expansion tank and remove it if necessary to prevent it from spilling out.
11. Apply a thin coat of heat resistant grease to the caliper guide surfaces, such as Liqui Moly, before installing the brake pads.
12. Remove the protective foil from the brake pad backing plate.
13. Caliper C-38. Install brake pads 1 into the guide 2 of the pads (see illustration).
14. Caliper C-II41. Install new pressure springs (see arrows in the illustration) and new brake pads 1 into the pad guide. Make sure the pads are seated correctly in the pressure springs.
15. Secure the caliper with new self-locking bolts, applying a tightening torque of 35 Nm, holding the guide pins from turning.
Attention! Self-locking bolts are included in the repair kit.
16. Install the removed wheel in accordance with the marks made during removal.
17. Screw in the wheel bolts and lower the car onto its wheels.
18. Tighten the wheel bolts in a criss-cross pattern to a torque of 120 Nm.
Attention! Press the brake pedal several times until you feel a strong resistance to pressing. When you do this, the brake pads are centered and they automatically set themselves to the working position.
19. Check the brake fluid level in the expansion tank. If necessary, top up the fluid to the maximum mark
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