Volkswagen Golf/Jetta/Cabriole 1990-1999

Brake Caliper

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REMOVAL & INSTALLATION





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Fig. Once the mounting hardware has been removed, pull the caliper away from the rotor



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Fig. Never let the caliper hang by the brake hose. Use wire to hang it as shown



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Fig. Lube the guide bolts with a synthetic disc brake caliper grease

The ABS hydraulic modulator is capable of self-pressurizing and can generate pressures above 3000 psi. any time the ignition switch is turned ON. Relieve the system pressure before testing or repairing the hydraulic system. Make sure the ignition switch stays OFF and pump the brake pedal 25-35 times to relieve the system pressure. Improper repair or test procedures can cause serious or fatal injury.

  1. Raise and safely support the vehicle on jackstands and remove the wheels.
  2.  
  3. Loosen the hydraulic line at the caliper, then remove the caliper from the carrier. With guide pin calipers, be sure to hold the pin with a back-up wrench when removing the caliper bolts. On cars with solid front rotors, remove the brake caliper to wheel bearing housing bolts.
  4.  
  5. Remove the caliper from the hydraulic line and cap the line to prevent fluid leakage.
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  7. Remove the brake pad wear sensor if equipped.
  8.  
  9. The carrier can be removed by removing the 2 bolts.
  10.  

To install:

  1. If removed, install the carrier. On standard brakes, tighten the carrier bolts to 52 ft. lbs. (70 Nm). On ABS brakes, tighten the carrier bolts to 92 ft. lbs. (125 Nm).
  2.  
  3. Thread the caliper onto the hydraulic line and hand-tighten it. Fit the caliper into place on the carrier.
  4.  
  5. On calipers with guide pins, tighten the bolts to 25 ft. lbs. (35 Nm). On calipers with sleeves and bushings, tighten the bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Tighten the hydraulic line and bleed the brakes.
  8.  

OVERHAUL




NOTE
Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!


NOTE
Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.
    4.  

  2.  



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Fig. For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



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Fig. Withdraw the piston from the caliper bore

  1. For the second method, you must rotate the piston to retract it from the caliper.
  2.  
  3. If equipped, remove the anti-rattle clip.
  4.  



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Fig. On some vehicles, you must remove the anti-rattle clip

  1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  2.  



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Fig. Use a prytool to carefully pry around the edge of the boot . . .



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Fig. . . . then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  



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Fig. Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To assemble:

  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
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  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  



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Fig. Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Install the caliper in the vehicle.
  2.  
  3. Install the wheel and tire assembly, then carefully lower the vehicle.
  4.  
  5. Properly bleed the brake system.
  6.  



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Fig. There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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