Date:         Fri, 9 Jul 2004 12:24:10 -0400
Reply-To:     Tim Demarest <tim.demarest@POBOX.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Tim Demarest <tim.demarest@POBOX.COM>
Subject:      Re: Squeaking Wheels When Brakes Not Applied
In-Reply-To:  <202916011.1089385553278.JavaMail.osg@spnode33>
Content-type: text/plain; charset=us-ascii; format=flowed

Josh,

        When I bought my '85 Westie, the brakes were nice and quiet. After a front
brake rebuild by a VW dealership in Virgina (cracked rotor on my way home
from a road trip with passengers... sticking around and fixing myself was
not an option), it squeaked every time I applied light brake pressure.

        About a year later, I replaced both calipers with rebuilt units (this was
the only part *not* replaced after the rotor crack). I discovered that the
wrench-monkeys at the dealer had left the shims out... and I have no idea
what pads they used. They certainly *charged* enough for OEM pads, but I
wasn't able watch them (since I was in NJ and the van was in VA).

        Since I was doing the work myself this time, I did the following:

        - Got a new set of pads from Bus Depot, which came with the 'anti-rattle
shims'.
        - Installed the rebuilt calipers.
        - Slightly chamfered the sharp edges of the pads before installing (use a
dust mask, you don't want to breathe this crap in)... this trick is not
Vanagon specific, I've heard it recommended as a general trick for quieting
down disc brakes. Since it only required a file and about five minutes of
my time, I gave it a try.
        - Lubed the back of the pads with brake lube, installed the shims behind
all pads.
        - Bled the brakes (ended up bleeding all four wheel cylinders and the
clutch slave, 'cause the fluid that came out at the front brakes was
*black*.. thank you Mitey-Vac for making this an easy one-man operation).

        Hasn't squeaked a bit since... but YMMV. As to whether the new calipers,
new pads, shims, lube or chamfering did the trick, that's anyone's guess.

Good Luck,

Tim