Volkswagen Air Cooled 1949-1969 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION





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Fig. Fig. 1 Exploded view of the front disc brake caliper used on type 3 models


CAUTION
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.

  1. Jack up the car and remove the wheel and tire.
  2.  
  3. Remove the brake pads.
  4.  
  5. Disconnect and plug the brake line from the caliper.
  6.  
  7. Remove the two bolts which secure the caliper to the steering knuckle and remove the caliper from the vehicle.
  8.  
  9. Installation is the reverse of the removal procedure. Bleed the brakes after the caliper is installed.
  10.  

OVERHAUL



Clean all parts in alcohol or brake fluid.

  1. Remove the caliper from the vehicle.
  2.  
  3. Remove the piston retaining plates.
  4.  
  5. Pry out the seal spring ring using a small prytool. Do not damage the seal beneath the ring.
  6.  
  7. Remove the seal with a plastic or hard rubber rod. Do not use sharp-edged or metal tools.
  8.  
  9. Rebuild one piston at a time. Securely clamp one piston in place so that it cannot come out of its bore. Place a block of wood between the two pistons and apply air pressure to the brake fluid port.
  10.  


CAUTION
Use extreme care with this technique because the piston can fly out of the caliper with tremendous force.

  1. Remove the rubber seal at the bottom of the piston bore using a rubber or plastic tool.
  2.  
  3. Check the bore and piston for wear, rust, and pitting.
  4.  
  5. Install a new seal in the bottom of the bore and lubricate the bore and seal with brake fluid.
  6.  
  7. Gently insert the piston, making sure it does not cock and jamb in the bore.
  8.  

When installing pistons on ATE and Teves calipers, make sure the relieved part of the piston is in the correct position to accept the retaining plate for the brake pads. See brake pad removal and installation for more information and illustration.

  1. Install the new outer seal and new spring ring.
  2.  
  3. Install the piston retaining plate.
  4.  
  5. Repeat the procedure on the other piston. Never rebuild only one side of a caliper.
  6.  

 
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