Date:         Tue, 25 Apr 2000 08:26:18 +0300
Reply-To:     Juha Koivisto <juha.koivisto@TEPCOMP.FI>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Juha Koivisto <juha.koivisto@TEPCOMP.FI>
Subject:      Total Brake Job (longish)
Content-Type: text/plain; charset="iso-8859-1"

I did total brake job during last weekend.  'Total' means in my case
changing the fluid, rear shoes and all seals and boots for all brake
cylinders.

At first my purpose is to change only hand brake cables which were
stucked..but..

I found all boots to be at the end of their lives => even some of the
rebuild kits were more expencive than new (Italian made) calibers I bought
them trusting original German manufacturing.

And even the boots were bad and there were lots of water, dust and rust in
there .. after cleaning calibers they were as new ones.

So I accomplished rear and front job and bleed the brakes..test..they were
worst than ever..you have to pump two-three times before solid.  Still air
in the system?  Feeling like Brent (sorry).  What went wrong?

In the last few weeks I have felt brake pedal gradually getting at the
bottom when keeping foot at pedal at traffic lights.  Also I noticed when
freeing brake pedal front calibers didn't do they little back movement as
they supposed to do.  So I suspect sealings of the main cylinder might be
gone..and they were!!

Changing seals (ATE/$7 USD only) of main cylinder makes a big change.

Now (after about 6 hrs work and with assistance of my wife and sons (6 and
9)) brakes are working like dream.

I encourage everyone who has lot of time and helpful wife to get ones brakes
going.  Time shows how long they last.

Juha Koivisto
88 Vanagon (Caravelle) 1,6TD (old school bus with 9 seats)
TURKU, FINLAND