Date:         Mon, 2 Apr 2007 08:04:16 -0700
Reply-To:     Shawn Wright <vwdiesels@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Shawn Wright <vwdiesels@GMAIL.COM>
Subject:      Re: Sticking front calipers
In-Reply-To:  <BAY125-F14A020E4A9128901BBF3D7A0610@phx.gbl>
Content-type: text/plain; charset=US-ASCII

On 1 Apr 2007 at 17:17, Dennis Haynes <d23haynes57@HOTMAIL.COM> wrote:

> I have never seen a piston fall out of a caliper while it was hangin with
> the pads reoved. it was either forced out by some one steeping on the pedal or
> there is another problem such as the master cylinder is all the way home or the
> inlet check is plugged and thermal expansion of the fluid pushed the pistons
> out.

My old pads were worn right out, so the cylinder was quite far out, and perhaps it was thermal
expansion that forced them out a bit more. They didn't come out to the point where fluid
gushed out, just to where I could feel them wobbling a bit at the end of the bore. I pushed
them back in, and in the process, took some rust/crud from inside the boot with them I think.

> Vanagon calipers are generally available, rebult, in a day or two through
> local parts suppliers. They are not terribly expensive for what they are.
> "Loaded" units come complete with pads and all the shims, silencers, etc. to do
> the job right. Repalce the hoses also if you can't remember when they were last
> done. Proper brake jobs include servicing the hydraulics. Sticking or rubbing
> brakes can also heat up and cuase failure of the front wheel bearings. A rotor
> can get hot enough to crack and have a piece fall out cuasing a sudden lock up
> as the broken rotor jams on the pad. Seen it. Going on a trip knowing you have
> brake problem is a major act of negligence. Get them fixed right.

I took them both apart, and found minor scuffing on both pistons, and a layer of rust that
came off easily with fine steel wool (ie: no pitting, surface still shiny). The rubber ring looks
good, except that a layer of rust on the outer edge underneath may have been forcing it into
the bore more than it should be, making it tight. They slid together much better, but are still
quite tight when all the way into the bore. Being one who likes to do jobs myself, and learn in
the process, I really would like to rebuild these. However, I am not foolish enough to risk my
family's safety over a pair of $75 rebuilds, so I will go that route this time.
For my reference, I would be interested in knowing more about the rebuild process, ie: how
tight should the pistons be, etc.

Thanks.


Shawn Wright
http://members.shaw.ca/vwdiesels
'88 Westy 1.6TD 5 speed
'85 Jetta Diesel 1.6NA