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Date:         Tue, 12 Oct 2004 12:57:00 -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: Brake noise when brakes not applied
Comments: To: Craig Oda <craigoda@GMAIL.COM>
In-Reply-To:  <b3a1e7ad04101208476c1a215b@mail.gmail.com>
Content-type: text/plain; charset=us-ascii; format=flowed

Craig,

You didn't mention the year of your van, but since you mention ATE or Girling calipers, can I assume it's an '85? If so read on ('85 is the only year I've done this on), if it's a later van, the front brakes are different, and I can't help you out, so ignore the rest of this message.

Pulling/re-installing the calipers is fairly easy, it's just two bolts. You'll want to pinch-clamp the rubber brake lines to keep the fluid in the rest of the system. I read through the Bentley before doing it, and don't remember any mention of replacing the bolts (I re-used mine).

Pulling the rotors on the early vans is a bit more involved, because the rotor and hub are one piece. This means that you'll be re-packing (and possibly replacing) the wheel bearings as well. The hub nut *is* a one-time-only fastener, as it gets peened to lock it to the hub. If you are replacing the bearings, you'll need to get new bearings and seals as well. You'll also need a hammer and soft metal (aluminum or brass) drifts to tap out the bearing races (and install the new ones), and some new wheel bearing grease.

Tim

At 08:47 AM 10/12/2004 -0700, Craig Oda wrote: >After about 40 miles of driving to Big Basin and about 10 miles of >mountainous up and down roads with heavy use of the brakes, my brakes >started to make a loud sound when the brakes weren't applied. Since I >was almost at the campsite, I just parked the van and enjoyed my stay. > On my way back from Big Basin, I went into Felton to see the skunk >train. First 20 minutes of the twisty drive were fine, then my front >right brake started to make an obnoxiously loud squealing sound when >the brakes were not applied. I'm concerned that the pad may be in >contact with the rotor. I bailed on the skunk train ride and surfing >in Santa Cruz and drove the van home. :-( It was okay though, >camping was fun enough for the weekend. > >I took off the two front wheels for inspection. The rotors and >calipers look fine from the outside. There is no sign of brake fluid >leakage. Brake fluid level is fine. I've changed the pads within the >last three months. > >I have not take the calipers off yet. However, I am thinking of doing >so. I have a couple of questions. I think there may be some air in >my brake system. It's kind of an inconvenience to keep asking my wife >to pump the brakes. (got young kids that we've got to deal with >around the van). I'm thinking of buying a Mity-Vac or something that >can help me perform this operation solo. Any thoughts on this? I may >just change all the fluid in the system as part of my maintenance. > >If I look at the Volkscafe site, there are Girling and ATE calipers. >The site says that the name is stamped onto the caliper. I can't find >this on my calipers. There is a VW logo and a set of Audi circles on >mine. Is there a stamp someplace there? > >If I take off the calipers, do I have to replace any bolts or nuts >that are one-time use? I was browsing through the Muir book and it >says that there are one-time use bolts for the buses. I'm wondering >if the vanagon has a similar setup? > >I'm thinking of taking out the calipers, cleaning them and changing >the gaskets. Is this a major task? I did this on an old Miata I >used to own and it was fairly easy. I've never taken the vanagon >brake calipers off. The volkscafe site says that the caliper rebuild >kit dust seals won't fit on the girling calipers. I would prefer to >install the dust seals. My calipers have different size bleeder >screws. From memory, the left is 6mm?? and the right is 8mm? or >maybe, 4mm and 6mm. Anyway, they're different sizes and I think that >one of the bleeder screws on the left is kind of dinged up. If I take >the calipers off the line, I will probably change the bleeder screws >and the seals. > >Maybe a good cleaning will help things. > >Should I do anything about the rotor? It looks fine with no >scratches. new rotors are fairly cheap, maybe $50 a piece. The last >shop I went to said that they would charge $35 to turn them. I can >probably find a cheaper shop if I look. > >Looking for general advice on the brakes.


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