Volkswagen Golf/Jetta/Cabriole 1990-1999

Brake Pads

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REMOVAL & INSTALLATION



Caliper with Guide Pins

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. Improper repair or test procedures can cause serious or fatal injury.

  1. Raise and safely support the vehicle on jackstands and remove the front wheels.
  2.  
  3. If the brake fluid reservoir level is near the maximum line, siphon some brake fluid from the reservoir to prevent overflowing when the piston is retracted into the cylinder bore.
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  5. Hold the lower guide pin with an open wrench and remove the bolt securing the caliper to the guide pin. Do not remove the top bolt.
  6.  
  7. Pivot the caliper up on the upper guide pin and slide the pads straight out to remove them.
  8.  

To install:

  1. Place the old pad against the piston and use a C-clamp to push the piston all the way into the bore. If the rubber boot is split, if there is fluid leaking from the caliper or if the piston will not move in the bore, the caliper must be rebuilt or replaced.
  2.  
  3. Fit the new pads into the carrier and pivot the caliper into place.
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  5. The original bolts are micro-encapsulated with a thread locking compound. Install a new bolt or clean the old bolt and apply a thread locking compound.
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  7. When tightening the bolt, be sure to use a back-up wrench to hold the guide pin. Tighten the bolt to 26 ft. lbs. (35 Nm).
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  9. Pump the brake pedal several times until the pedal is firm, then add new brake fluid as required.
  10.  

Caliper with Sleeves and Bushings


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Fig. Loosen the caliper mounting bolts



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Fig. Use caution around the brake hoses. Do not nick, crimp, or twist the exterior rubber case of the hose



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Fig. Note the position of each bolt removed



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Fig. Pivot the caliper up and then pull it out to remove



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Fig. Slide the pads out of the caliper



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Fig. Always reinstall a shim. This thin piece of metal is essential to quiet brake operation

  1. Raise and safely support the vehicle on jackstands and remove the front wheels.
  2.  
  3. If the brake fluid reservoir level is near the maximum line, siphon some brake fluid from the reservoir to prevent overflowing when the piston is pushed into the cylinder bore.
  4.  
  5. Put a large C-clamp around the caliper so it contacts the caliper body and the outer brake pad. Tighten the clamp to push the piston into the bore. Remove the clamp and push the caliper in and out to make sure the sleeves and bushings move freely.
  6.  
  7. With a 6mm Allen® socket, remove the 2 bolts holding the caliper to the carrier. Push the caliper up and pivot the bottom of the caliper out of the carrier.
  8.  
  9. Hang the caliper from the front spring with a piece of wire. DO NOT let the caliper hang by the hydraulic line.
  10.  
  11. Remove the anti-rattle springs and the pads from the carrier and note their location.
  12.  

To install:

  1. Fit the anti-rattle springs into place and slide the new pads onto the carrier. The tang should be towards the inner pad.
  2.  
  3. Fit the caliper into place at the top and push up so it can be pivoted into place at the bottom. The tabs on the anti-rattle springs should be pushing against the inside of the caliper.
  4.  
  5. Make sure the caliper mounting bolts are clean. Install the bolts and tighten them to 18 ft. lbs. (25 Nm).
  6.  
  7. Pump the brake pedal several times until the pedal is firm, then add new brake fluid as required.
  8.  

INSPECTION



The brake pad wear limit is 0.080 inches (2mm). If the pads show signs of heat cracks or if they are worn unevenly, check the caliper for a sticking piston or guides. Check the caliper for signs of fluid leakage or damage to the dust seal. Also check the rotor for signs of heat cracks or discoloration. The minimum allowed thickness of solid brake rotors is 0.393 inches (10mm). Maximum allowed run-out is 0.002 inches (0.06mm). The minimum allowed thickness of vented brake rotors is 0.708 inches (18mm). Maximum allowed run-out is 0.002 inches (0.06mm).

 
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