Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION




CAUTION
The ABS hydraulic modulator is capable of self-pressurizing and can generate pressures above 3000 psi anytime the ignition switch is turned ON. Relieve the system pressure before testing or repairing the hydraulic system. Improper repair or test procedures can cause serious or fatal injury.

  1. Disconnect the negative battery cable.
  2.  
  3. If equipped with ABS, make sure the ignition switch stays OFF , and pump the brake pedal 25-35 times to relieve the system pressure.
  4.  
  5. Raise and safely support the vehicle on jackstands. Remove the wheels.
  6.  
  7. Disconnect the parking brake cable.
  8.  
  9. Loosen the hydraulic line using a flare nut or line wrench.
  10.  
  11. Use a back-up wrench to hold the guide pins and remove the caliper bolts.
  12.  
  13. Lift the caliper off the carrier and unscrew it from the hydraulic line.
  14.  
  15. Installation is the reverse of removal. Use new caliper mount bolts or clean the old bolts and apply a thread locking compound. Torque the bolts to 26 ft. lbs. (35 Nm).
  16.  
  17. Bleed the brakes.
  18.  

OVERHAUL



See Figure 1

  1. Place the caliper in a vise or holding fixture.
  2.  
  3. Make sure the bleeder screw will loosen. If the screw breaks off, the caliper will have to replaced.
  4.  
  5. Remove the piston dust seal.
  6.  
  7. Unscrew the piston from the caliper. Do not attempt to blow the piston out with compressed air.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the rear caliper assembly

  1. Remove the piston seal from the bore. Be careful not to damage the finished bore surface.
  2.  
  3. Clean all components with denatured alcohol that leaves no residue and dry with compressed air.
  4.  

On calipers with guide pins, the pins are part of the carrier and are usually not available separately.

  1. Remove any rust or corrosion from the piston and bore with very fine emery paper and clean again. Excessive corrosion will cause the caliper to leak. Replace caliper if the corrosion can not be removed with fine emery paper.
  2.  

If the caliper is leaking at the parking brake lever, the caliper must be replaced.

  1. Install the piston seal into the groove and make sure it is not twisted.
  2.  
  3. Lubricate the piston and bore with new brake fluid. Any thing else may cause damage to the rubber.
  4.  
  5. Install the piston by screwing it onto the parking brake pushrod.
  6.  
  7. Insert the inner lip of the dust seal into the groove in the brake caliper. The outer lip must slip into the groove in the piston. Make sure the dust seal is secure before installing the caliper.
  8.  

 
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