216 / 142 Installation instructions VW Golf 1 Cabrio Caddy 14d Jetta on the G60 brake system

Installation instructions for article no.216 and article no.142, here you will learn how to proceed step by step.

Dismantling:

Old brake system (brake disc, brake caliper and brake caliper carrier).

Remove or process the air baffle or brake baffle or anchor plate (we prefer removal, as the ventilation of the brake is better ensured).

!!Important!!:

Make sure that there are no rust or paint residues on the bolts of the steering knuckle or wheel hub. If this is the case, please clean them. Then check the threads of the steering knuckle for damage.

What do you need?

Depending on your technical knowledge, approx. 1-2 hours of time

Torque spanner with suitable attachments

Liquid threadlocker

Preparation:

Tools

Ratchet with extension (to loosen and tighten the caliper)
15mm NUT, for loosening the old caliper holder
18mm or 19mm NUT, for mounting the G60 caliper bracket
6mm Allen key (best use for the ratchet!)
13mm spanner, for mounting the brake calliper
15mm open-ended spanner to hold the caliper in place when mounting the caliper
11mm ring spanner for bleeding the brake caliper

Assembly:

1. Remove the old brake calliper.

2. Remove the air baffle or machine it to fit.

3. Due to VW's manufacturing tolerances, the brake calliper mounting must be checked for parallelism, which can be recognised by an air gap when one side is screwed on with only one countersunk screw. This can also be seen when the adapter is screwed to the steering knuckle with only one countersunk screw. It may then be in contact.

4.If there is a gap when checking the parallelism, a washer must be placed between the adapter and the brake caliper mount. This is best done at the lower mounting hole. This way the parallelism that was not there before will be. Where the washer is used, the longer countersunk screw must be used. If necessary, the brake caliper mount on the steering knuckle can also be adjusted.

5. Mount the brake disc by securing two opposite wheel bolts. If you only use one bolt for fixing, it is possible that the brake disc will not lie flat everywhere and will be tight on one side.

6. Attach the G60 brake caliper holder to the adapter from the rear using the screws.

7. Check whether the brake disc runs freely between the brake caliper holder at the same distance after assembly. There should be no grinding or similar noise.

8. When everything is in order, dismantle the brake and secure countersunk screws with liquid threadlocker.

9. Reassemble the brake install the caliper and pads.

Then you can reconnect the brake lines and bleed the brake completely. With this conversion, it is recommended that you convert directly to steel braided brake lines.

Click here to go directly to the matching steel braided lines ( click here )

These have the following advantages:

No pressure loss when brakes are applied, noticeably precise pressure point
No swelling as with rubber lines
cost savings, as steel braided lines have an almost unlimited service life and do not have to be replaced every 3-5 years.
Shorter braking distance
Protection against martens
Optics

Now you can mount the rim again.

When you mount the rim, make sure that the brake caliper does not rub against the rim. If this is the case, you can counteract this with wheel spacers, if necessary, so that the rim has enough distance to the brake calliper. Click here for our wheel spacers (click here)

This means that the conversion with the G60 brake calipers and matching brake disc is almost complete.

Finally, the free movement of the new brake system must be checked. To do this, turn the vehicle in completely to the left and right and check that nothing is dragging anywhere, or that nothing is touching anything, e.g. the suspension joint, wishbone, etc.

The whole thing must be done in the sprung and unsprung condition.

If a collision should occur at full steering angle, it may be possible to counteract it quite simply with steering angle limiters. (click here for our steering angle limiters)