WARNING! If you use the following guide in any way, you do so at your own risk. Although we make every effort to make our guides as accurate as possible we cannot guarantee that they 100% correct. TorqueVW™ cannot be held liable for faults or third party injury caused by using this guide. If you do not feel confident carrying out the following work get a professional to do it.
First thing to do is remove the wheel and raise the car.
SAFETY - The car should be raised using a trolley jack and ideally use axle stands so that the car is stable, as some effort may be needed to remove old discs from the hubs.
Turn the steering to the full lock position so that the brake calliper is proud of the wheel arch. This will make it easier to access the 17mm bolts fixing the calliper to the hub. Carefully remove the 17mm bolts and rest the calliper in a position ensuring that you do not damage the brake piping.
Locate the single retaining screw holding the disc in position on the hub. If the disc is old you my find that the screw is showing signs of corrosion. If this is the case then care should be taken to ensure that you do not strip the head of the screw. One way of doing this is to use a hammer to give the screwdriver a few sharp knocks into the screw before applying any torque to remove it.
With the screw removed the disc should come away from the hub. If the disc is old you may find that it needs some persuading to come off. Try spraying some lubricant around the join between the disc and hub. If this does not help then you may need to tap a block of wood against the disc using a hammer or mallet to loosen the disc away from the hub.
If the disc has a grease protective coating on it then this will need removing with some white spirit before fitting. Once cleaned the disc can be fitted to the hub.
Apply some copper grease to the face of the hub. This will help prevent the disc binding to the hub and make future removal easier.
Fit the disc to the hub and insert the disc retaining screw. Tighten screw.
The first thing to do here is locate the brake fluid reservoir in the engine bay and remove the top. This allows you push the brake piston back more easily. It may be sensible at this point place a rag around the reservoir to catch any brake fluid that spills out over the top of the reservoir when you push the piston back. CAUTION - Brake fluid hazardous and will damage paintwork. Spillage should be avoided and cleaned up immediately. Avoid contact with skin.
Pull the old pads out of the calliper. This should be quite easy as they are only held in position by springs.
Using two 14mm spanners undo one of the bolts in the outermost positions on the calliper.
This will allow you to open up the calliper and gain access to the piston more easily.
Before you can fit new pads you will need to push back the brake piston. If this is not done you won’t be able to fit the calliper back over the new disc as the gap between the new fatter pads will not be as wide as the disc!
First remove the thin metal cap covering the piston.
Using a G-Clamp (take care as you do not want the clamp to damage any part of the calliper or brake pipe) carefully wind back the piston. As you wind the piston back the brake fluid level in the reservoir will rise. At this point it’s useful if a second person can be watching the level to warn you if it is getting close to overflowing from the reservoir. If it is you may need to remove any excess fluid.
With the piston wound back sufficiently replace the piston cap and close up the calliper re-fitting the 14mm bolt. Re-fit the brake fluid reservoir cap.
The new pads can now be put into place. Ensure they are pushed back to the edges of the calliper and that they are not fitted at an angle.
Replace brake calliper over the new disk ensuring that the brake piping is not twisted or damaged. Tighten the two 17mm bolts to the manufactures torque setting.
Repeat steps 1 to 10 for the other wheel.
Turn the ignition to position 2 and gently pump the brake pedal to take up any excess space between the pad and disc. Check the brake fluid level in the reservoir and top up to the required level if necessary. Check your vehicle handbook for the correct brake fluid to use.
Fit the wheel and lower the car. Ensure that the wheel bolts are torqued sufficiently.
Note: Do not brake hard for a few miles after new discs have been fitted. New discs and pads take a little time to bed in and will not perform as well initially. Always leave extra distance to brake for the initial 100 miles or so after new brakes have been fitted.
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