Volkswagen Parts Catalog Volkswagen Accessories Catalog Volkswagen Tech Information Volkswagen Tech Forums
 
Follow Pelican Parts on Facebook Follow Pelican Parts on Twitter Follow Pelican Parts on Instagram Follow Pelican Parts on YouTube Follow Pelican Parts on Pinterest Follow Pelican Parts on Tumblr
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
Bookmark and Share

Pelican Technical Article:

Rear Brake Caliper Replacement

Steve Vernon

Time:

3 hours3 hrs

Tab:

$300

Talent:

**

Tools:

17mm, 15mm, 13mm wrench, flat head screwdriver, 11mm flared nut wrench

Applicable Models:

VW GTI (2006-09)

Parts Required:

Brake calipers

Hot Tip:

Check your brake pads and discs when replacing your calipers

Performance Gain:

Better braking

Complementary Modification:

Brake disc replacement, install stainless steel brake lines

Replacing the rear brake calipers on the GTI is an easy DIY job. The rear caliper incorporates the parking brake, which is essentially a cable-operated method of squeezing the brake pads against the rotors, as opposed to the primary hydraulic system. If you have a sticking brake, one wheel that locks up consistently before the others and uneven brake pad wear, you may have a bad caliper. Check your brake lines and give the system a good flush and bleed before just replacing the caliper. Caliper boots can also get damaged and lead to damage to the piston. If you find brake fluid leaking from your caliper, repair or replace it immediately.

You are going to be opening the hydraulic lines on the brake system when replacing your caliper, so you must properly bleed your brakes before driving the car again. Do NOT attempt to drive the car after performing this work without first properly bleeding your brakes. Please see our article on bleeding your brakes for help.

Begin by safely raising and supporting your vehicle. Then remove the rear tires. Please see our article on safely raising and supporting your car. Wear safety glasses anytime you work under your vehicle.

This photo illustrates the rear brake system.
Figure 1

This photo illustrates the rear brake system. You can see the rotor (red arrow) the caliper (green arrow) and the brake pads (yellow arrow, one showing, and one on the other side of the rotor).

The caliper (green arrow) is attached to the caliper mount by two bolts.
Figure 2

The caliper (green arrow) is attached to the caliper mount by two bolts. It also has the brake line (yellow arrow) and parking brake (red arrow) attached. You will need to remove both of these lines to replace the caliper.

Remove the parking brake ball end (yellow arrow) and cable clip (red arrow) from the caliper.
Figure 3

Remove the parking brake ball end (yellow arrow) and cable clip (red arrow) from the caliper. Begin by releasing the parking brake. There will be enough slack that you can push the parking brake arm (green arrow) forward and slide the ball end of the cable out from its socket. Next squeeze the plastic clips together (red arrow) and slide the cable back out from the mount on the caliper. This will allow you to remove the cable from the caliper and allow you to remove the caliper from the vehicle.

To remove the brake line from the caliper first use a flathead screwdriver and pry the brake line clip up and off the line (yellow arrow).
Figure 4

To remove the brake line from the caliper first use a flathead screwdriver and pry the brake line clip up and off the line (yellow arrow).

The rubber flexible line attaches to the hard line at the bracket on the caliper.
Figure 5

The rubber flexible line attaches to the hard line at the bracket on the caliper. Support the rubber line fitting with a 17mm wrench while using an 11mm flared nut wrench to separate the hard line from the rubber line at the bracket (yellow arrow). Then push the rubber line back out from the bracket. You can transfer the small hard line (green arrow) from the old caliper to the new caliper once you have the caliper off the vehicle.

There are two 13mm bolts holding the caliper to the mounting bracket (yellow arrows).
Figure 6

There are two 13mm bolts holding the caliper to the mounting bracket (yellow arrows).

Use a 15mm wrench to hold the guide bolts (yellow arrow, one shown) while removing the two 13mm bolts (red arrow, one shown).
Figure 7

Use a 15mm wrench to hold the guide bolts (yellow arrow, one shown) while removing the two 13mm bolts (red arrow, one shown).

Pull the caliper (red arrow) off from its mount leaving the brake pads (yellow arrow).
Figure 8

Pull the caliper (red arrow) off from its mount leaving the brake pads (yellow arrow). Depending on the condition of the pads and whether they have anti-squeal backs you may need to use a fair amount of wiggling and force to get the caliper off. Transfer the hard brake line from the old caliper to the new one.

Pull the guide pins and rubber boot from the mount (yellow arrow).
Figure 9

Pull the guide pins and rubber boot from the mount (yellow arrow). Inspect the pin for any dirt, debris or rust. Clean the bolt and apply new grease as needed. Inspect the boot for rips and other damage. Repair as needed and reinstall the guide bolts into the mount and install the new caliper.

You will need to adjust the brake cable on the new caliper so that the distance between the stop on both rear calipers is between 1-3mm (red arrows).
Figure 10

You will need to adjust the brake cable on the new caliper so that the distance between the stop on both rear calipers is between 1-3mm (red arrows). You only need to perform the adjustment once as the parking brake is self-adjusting after the initial setting. Please see our article on parking brake adjustment for additional assistance.

Installation is the reverse of removal.
Figure 11

Installation is the reverse of removal. You now must bleed the brake system. Please see our article on brake bleeding for further assistance. Note: You must bleed the brakes before driving. Do NOT attempt to drive the vehicle before properly bleeding the brakes.

Bookmark and Share

  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Project/Wish List]
  [Privacy Statement]  [Contact Us] [About Us] [Shipping] [Careers]

Copyright © Pelican Parts Inc. -    DMCA Registered Agent Contact Page

Page last updated: Wed 12/7/2016 02:38:51 AM