Volkswagen Cars 2000-05

Brake Drums

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Inspection



  1. Check the drum for scoring or warping. Also check for signs of heat cracking or discoloring.
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  3. The maximum inside diameter after resurfacing must be no more than 7.106 inches (180.5mm).
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  5. The maximum wear limit is 7.126 inches (181mm).
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Removal & Installation



Some brake shoes contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  1. Raise and safely support vehicle and remove the rear wheels.
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  3. Insert a small pry tool through a wheel bolt hole and push up on the adjusting wedge to slacken the rear brake adjustment.
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  5. Remove the grease cap, cotter pin, locking ring, axle nut and thrust washer. Carefully remove the bearing and put all these parts where they will stay clean.
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  7. Carefully remove the drum by pulling it straight off the hub. If the drum is stuck, rock it side to side and top to bottom as you are pulling on it. If it still does not come off you may need to slacken the shoes some more by turning the adjuster with a spooning tool.
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  9. Before installing, if any brake dust has fallen onto the axle, wipe off all the grease and apply a coat of new high temperature bearing grease. Install the parts in the reverse order of removal.
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NOTE
When tightening the axle nut, the thrust washer must still be movable with a small screw driver. Spin the drum and check that the thrust washer can still be moved.

  1. When installing the locking ring, keep trying different positions of the ring on the nut until the cotter pin goes into the hole. Don't turn the nut to align the locking ring with the hole in the axle. Use a new cotter pin.
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CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Before servicing the vehicle, refer to the Precautions Section.
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  3. Remove the rear wheels.
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  5. Insert a small pry tool through a wheel bolt hole and push up on the adjusting wedge to slacken the rear brake adjustment.
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  7. Remove the grease cap, cotter pin, locking ring, axle nut, thrust washer, and outer bearing.
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  9. Remove the drum.
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To install:

  1. Install the drum. Install the outer bearing, washer, and nut.
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  3. Install the lock ring and cotter pin. Install the grease cap.
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  5. Install the wheels.

    Click image to see an enlarged view

    Fig. Rear drum brakes-New Beetle shown

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