Volkswagen Golf/Jetta 2 manual

Brake discs - examination, removal and refitting
Braking system / Brake discs - examination, removal and refitting


Front discs
1 Jack up the front of the vehicle and support it on axle stands (see УJacking and vehicle supportФ). Apply the handbrake and remove both front wheels.

2 Using an Allen key, unscrew the upper and lower caliper securing bolts. Withdraw the caliper and tie it clear of the disc. Do not allow the weight of the caliper to stretch or distort the brake hose.

3 Rotate the disc and examine it for deep scoring or grooving.

4 Using a micrometer, check that the disc thickness is not less than the minimum amount specified.

5 Remove the cross-head screw and withdraw the brake disc from the hub (see illustration).

4.5 Front brake disc retaining screw (arrowed)
4.5 Front brake disc retaining screw (arrowed)

6 If necessary, the splash guard can be removed from the wheel bearing housing by unscrewing the three bolts.

7 Refitting is a reversal of removal. Ensure that the mating faces of the disc and hub are clean.

Rear discs
8 Chock the front wheels, jack up the rear of the vehicle and support it on axle stands.

Remove both rear wheels.

9 Remove the caliper and tie it clear of the disc. Do not allow the weight of the caliper to stretch or distort the brake hose.

10 Rotate the disc and examine it for deep scoring or grooving.

11 Using a micrometer, check that the disc thickness is not less than the minimum amount specified.

12 Using a dial gauge or metal block and feeler blades, check that the disc run-out measured on the friction surface does not exceed the maximum amount specified.

13 Unbolt and remove the rear brake carrier.

Use a screwdriver and prise free the hub cap (see illustration).

4.13 Prise free the hub cap . . .
4.13 Prise free the hub cap . . .

14 Straighten and extract the split pin, then withdraw the locking ring (see illustration) .

4.14 . . . remove the split pin and lock ring . . .
4.14 . . . remove the split pin and lock ring . . .

15 Undo the hub nut and then withdraw the thrustwasher and outer taper bearing race (see illustration).

4.15 . . . followed by the outer washer and bearing
4.15 . . . followed by the outer washer and bearing

16 Withdraw the disc from the stub axle.

17 Unless a disc is being renewed after a low mileage due to damage or other defect, both discs must be renewed at the same time.

18 Refer to the following Section for hub bearing replacement.

19 Lubricate the stub axle with grease then fit the disc over it, taking care not to damage the inner oil seal lips.

20 Lubricate the outer taper roller bearing with grease and locate it onto the stub axle against its bearing outer race.

21 Refit the thrustwasher, engaging the inner lug with the groove in the stub axle. Hand tighten the securing nut to the point where the thrustwasher can just be moved with a screwdriver and finger pressure but without levering it. Check that the disc rotates freely without binding or excessive endfloat, then locate the locking ring over the nut and insert a new split pin to secure.

22 Half fill the hub cap with bearing grease and tap it carefully into position .

23 Before refitting the brake carrier, check that the protective caps and guide pins are not damaged. If they are, then the carrier must be renewed. Locate and fit the carrier retaining bolts, tightening to the specified torque setting.

24 The caliper can now be refitted.


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