Repairing rear brake caliper — VW

VW
Golf
1984
Jetta
1984
Running gear
Running gear
Edition
11.2005
Repairing rear brake caliper
Note
Apply thin coat of brake cylinder paste to brake cylinder, piston and seals.
When carrying out repairs install all parts supplied in repair kit.
New brake calipers are filled with brake fluid and are pre-bled.
When carrying out repairs it is essential to appropriately pre-bleed the brake calipers (without brake pads) before installing in the vehicle
Fig.
.
Self-locking bolts, 35 Nm
Renew.
When loosening and tightening, counter hold on guide pin.
Oil seal
Remove with a plastic wedge
Fig.
.
Piston with automatic adjustment
Remove from brake caliper housing:
Vehicles up to 07.87
Fig.
.
Vehicles as of 08.87
Fig.
.
Installing into brake caliper housing
Fig.
.
Protective cap
Position with outer sealing lip onto piston
Fig.
.
Insert with inner sealing lip into groove in brake caliper housing
Fig.
.
Do not damage sealing lips when positioning or inserting.
Dust cap
Bleed valve
Apply thin coat of brake cylinder paste to threads before screwing in.
Brake caliper housing with lever for handbrake cable
If a leak exists at the handbrake cable lever, renew brake caliper housing.
After repairing, pre-bleed brake caliper housing
Fig.
Guide pin
Lubricate before installing protective cap
Protective cap
Insert onto brake carrier and guide pin
Brake carrier with guide pin and protective cap
Supplied as replacement part, assembled with sufficient grease on guide pins.
If protective caps or guide pins are damaged, install repair kit. Use grease sachet supplied to lubricate guide pins.
Removing piston from brake caliper housing, vehicles up to 07.87
Unscrew piston by turning anti-clockwise.
Removing piston from brake caliper housing, vehicles as of 08.87
Unscrew piston by turning anti-clockwise.
Taking out sealing ring
Use reworked
wedges
V.A.G 1474/5
to do this.
Note
Reworking
wedges
V.A.G 1474/5
Fig.
Place protective seal with outer sealing lip on piston.
Inserting inner sealing lip of protective cap into grove in brake caliper housing
Use reworked
wedges
V.A.G 1474/5
to do this.
When doing this hold piston in front of caliper housing.
Note
Reworking
wedges
V.A.G 1474/5
Fig.
Installing piston into brake caliper housing
Screw piston in to stop by turning clockwise. Press firmly onto piston while screwing it in.
In vehicles as of 08.87, use tool
3131
instead of Allen key
Fig.
Note
The outer sealing lip of the protective cap will then lock in the groove on piston.
Pre-bleeding brake caliper
Open bleed valve and fill with brake fluid using a standard bleed bottle until brake fluid flows out of the threaded hole (brake hose connection) without bubbles. Close bleed valve.
Note
Position brake caliper as illustrated to pre-bleed.