Volkswagen Workshop Service and Repair Manuals

Tools

• ◆ VW 402
• ◆ VW 411
• ◆ VW 418a
• ◆ VW 431

• ‒ Remove nuts from drive shafts.
• ‒ Detach brake lines and hoses to front brakes and remove brake drums, wheel cylinders and shoes.
• ‒ Remove wheel bearing housings complete with backplates.
• ‒ Press wheel hubs out.

A = Parallel bars

• ‒ → Pull bearing inner races off the hubs.

Tools

• ◆ VW 412
• ◆ VW 420
• ◆ VW 433
• ◆ VW 402

• ‒ Install one circlip on outside of new wheel bearing housing, press new bearing in and fit second circlip.
• ‒ Install splash plate.

Tools

• ◆ VW 402
• ◆ VW 412
• ◆ VW 432
• ◆ VW 519

• ‒ Press hub into the new wheel bearing housing.
• ‒ Install bearing housing.
• ‒ Attach new hoses to the calipers.
• ‒ Install brake discs and calipers. Insert rubber grommets in the hose brackets and connect brake hoses to lines on body.

• ‒ Remove residual pressure valves from master cylinder. Remove internal parts (break sleeve out with pliers) and screw valve housing in again as adaptor.
• ‒ On vehicles up to Chassis No. 175 3 287 383 install brake pedal (distance a = 47 mm) with push rod (b = approx. 140 mm) and return spring .
  Adjust push rod play (2 - 4 mm at pedal plate).
• ‒ Bleed brake system.
• ‒ Adjust wheel alignment.
• ‒ Check whether the modification has to be entered in the vehicle documents.

Note:

Contrary to the factory fitted disc brakes, the kit contains discs, calipers and pads from the Polo and drum brake front wheel hubs from the Golf. Ensure that the correct parts are used when carrying out repairs to converted vehicles.