Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Brake Disc (Rotor)

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REMOVAL & INSTALLATION



  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle, then remove the rear wheels.
  4.  
  5. Remove the rear brake caliper and hang it from the rear spring with wire. Do not let the caliper hang by the hydraulic line.
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  7. 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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  9. Slip the rotor/hub off the axle.
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To install:
  1. 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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When tightening the axle nut, the thrust washer must still be movable with a small screwdriver. Spin the rotor 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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  3. Connect the battery cable.
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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 and reinstall the wheel bolts (tightened to 65 ft. lbs.) to retain the rotor to the hub.
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  3. Mount the dial indicator securely to the caliper. The gauge stem should touch the rotor about 1/2 in. (13mm) from the outer edge.
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  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.
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  7. Brake rotors which have excessive radial run-out, sharp ridges, or scoring can be refinished. Initial 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. The standard solid rotor is 0.472 in. (12mm) thick. It should not be ground to less than 0.413 in. (10.5mm).
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