Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Brake Pads

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle, then remove the rear wheels.
  4.  
  5. Remove a sufficient quantity of brake fluid from the master cylinder reservoir to prevent it from over flowing when installing the pads. This is necessary as the caliper piston must be forced into the cylinder bore to provide sufficient clearance to install new pads.
  6.  
  7. Remove the parking brake cable clip from the caliper. Disconnect the parking brake cable.
  8.  
  9. Hold the guide pin with a back-up wrench and remove the mounting bolts from the brake caliper.
  10.  



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Fig. Fig. 1: Hold the guide pin with a back-up wrench and remove the mounting bolts from the caliper

  1. Remove the caliper and secure it to the side. Remove the brake pads.
  2.  



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Fig. Fig. 2: Removing the brake pads

  1. Check the rotor for scoring and resurface or replace as necessary. Check the caliper for fluid leaks or a damaged dust seal. If any damage is found, the caliper will require overhauling or replacement.
  2.  

To install:
  1. Retract the piston into the housing by rotating the piston clockwise.
  2.  



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Fig. Fig. 3: Retracting the piston into the housing

  1. Carefully clean the anchor plate and install the new brake pads onto the pad carrier.
  2.  
  3. Install the caliper to the pad carrier using new self-locking bolts or a thread locking compound. Torque to 26 ft. lbs. (35 Nm).
  4.  
  5. Attach the hand brake cable to the caliper. It may be necessary to back off the adjustment nuts at the hand brake handle.
  6.  
  7. Fill the reservoir with brake fluid and pump the brake pedal about 40 times with the engine not running to set the piston. Setting the piston with the power assist could cause the piston to jam.
  8.  
  9. Check the parking brake operation, adjust the cable if necessary.
  10.  
  11. Connect the battery cable.
  12.  
  13. Road test the vehicle.
  14.  

INSPECTION



  1. The brake pad wear limit is 0.080 in. (2.0mm).
  2.  
  3. If the pads show signs of heat cracks or if they are worn unevenly, check the caliper for a sticking piston or guides.
  4.  
  5. Check the caliper for signs of fluid leakage or damage to the dust seal.
  6.  
  7. Check the rotor for signs of heat cracks or discoloration.
  8.  
  9. Minimum allowed thickness of solid brake rotors is 0.393 in. (10mm). Maximum allowed run-out is 0.002 in. (0.06mm).
  10.  

 
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