Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Brake Disc (Rotor)

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REMOVAL & INSTALLATION



See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle, then remove the wheel.
  4.  
  5. Remove the brake caliper, pads and the pad carrier.
  6.  
  7. With the wheel removed, the rotor is held in place only with a countersunk screw threaded into the hub. Remove the screw and slide the rotor off.
  8.  

To install:
  1. Install the rotor screw, clean the screw threads with a wire brush and install the screw. Torque the screw to 15 ft. lbs. (20 Nm).
  2.  
  3. Reinstall the caliper and pump the brake pedal several times to bring the pads into adjustment. Road test the vehicle.
  4.  

INSPECTION



Brake rotors may be checked for lateral run-out while installed on the car. This check will require a dial indicator gauge and stand to mount it on the caliper. VW has a special tool for this purpose which mounts the dial indicator to the caliper, but it can also be mounted on the shaft of a C-clamp attached to the outside of the caliper.

  1. Remove the wheel, then reinstall and tighten the wheel bolts to 65 ft. lbs. (88 Nm), in order to retain the rotor to the hub.
  2.  
  3. Mount the dial indicator securely to the caliper. The gauge stem should touch the rotor about 1/2 inch (13mm) from the outer edge.
  4.  
  5. Rotate the rotor and observe the gauge. Radial run-out (wobble) must not exceed 0.002 in. (0.06mm). A rotor which exceeds this specification must be replaced or refinished.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the screw ...



Click image to see an enlarged view

Fig. Fig. 2: ... then slide the rotor off

  1. Brake rotors which have excessive radial run-out, sharp ridges, or scoring can be refinished. First grinding must be done on both sides of the rotor to prevent squeaking and vibrating. Rotors which have only light grooves and are otherwise acceptable can be used without refinishing.
  2.  

 
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