Custom Volkswagen Parts :: Airkewld.com

It is recommended to read and comprehend this install guide BEFORE beginning the disc brake conversion. This set was tested for use on the rear of a Volkswagen Type 1 Beetle or Ghia.

INSTALLATION INSTRUCTIONS:

1. Break all front wheel nuts free approx 1/2 turn with tires on the ground, parking brake applied. Then, jack up the rear of the car and place it securely on jack stands. Remove each rear wheel.
2. Remove the cotter pin, axle nut, e-brake cable, drum and backing plate from the axle.
3. Clean all grease/ residue with a quality brake parts cleaner.
4. You will need to remove and install the supplied oil seal into your bearing cap. Install the oil sling, (if applicapable) gaskets and o-rings per the Chilton manual.
5. Attach the caliper mounting plate to the axle tube with the bearing cap and the OEM hardware. Torque to 35 ft. lbs after initial tightening in a cross pattern.
6. Grease the seal and install the seal race. Make sure grease it so it does not burn off.
7. Install a chromoly spacer on the axle and slide the rotor on. Install another chromoly spacer bevel side in and install/tighten the axle nut with an impact gun. Check to make sure the rotor is not touching anything while tightening. Some late models need to surface the top of the bearing cap for added clearance on the back of the rotor. Other applications might need a second chomoly spacer.
8. Install the cotter pin in the axle.
9. You are now ready to test fit the brake caliper. There is an assortment of washers/ shims supplied with the kit. It is of UTMOST IMPORTANCE that the caliper is fitted so that A, the rotor rides in the exact center of the caliper cutout on both the top and bottom of the caliper and B, the pads contact the rotor dead flat to surface; IE, it doesn't contact the top of the pad to the rotor while not contacting at the bottom of the pad, or vice versa. Thus, the brake caliper must be installed in parallel with the brake disc.
10. Once it is determined that the caliper is spaced such that this has been achieved, the caliper can be fixed to the mounting plate with the appropriate shims using a high- temperature thread locker and torqued to 35 ft lbs.
11. Run the supplied e-brake cables through the factory locations and hook up to the caliper. Install the circlip provided to keep the cable in place.
12. If you purchased the stainless steel brake hoses, the banjo end will be mounted to the caliper in between two copper crush washers. Do not over tighten the supplied bolt. If you did not purchase these, you will need to straighten the factory steel hard line and rebend it to fit your new application.
13. Allow all fluid to drain from the brake master cylinder and reservoir. Flush system with fresh fluid. Fill the master cylinder reservoir with fresh DOT-4 fluid.
14. Bleed the front brakes first when doing four wheel disc brakes. Start with the right side front, left side front, right side rear and left side rear. Check and top off reservoir.

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