Question about 2004 Volkswagen Jetta

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2004 Jetta 2L gas. From day one front caliper pistons retract 0.5 mm from the rotor surface when the brake pedal is released. New rotors and pads improve it somewhat but ABS newer actuates on dry pavement: wheels may be blocked on wet road only. Do not tell be obvious things at to bleed the system. Air bubbles have nothing to do with it, I bled the ABS with vacuum fixture, there was no effect.

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  • 09escape
    09escape Apr 21, 2014

    Hi Vincent. Your description is how normal system works. It is not in my vehicle. The brake pedal touches the floor diring the emergency braking and the emergency stopping distance is twice longer than on my another car. Bleeding does not help and new rotors/calipers do not help. To me it is symptomatic. I think to replace the master cylinder. Do you think it is correct idea? Thanks in advance,

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  • Volkswagen Master
  • 354 Answers

When you say.." newer actuated on dry pavement...." what do you mean? Do you mean it doesn't skid or it does skid?

Posted on Apr 17, 2014

  • 3 more comments 
  • 09escape
    09escape Apr 19, 2014

    It never skids on dry pavement. There is not enough pressure to block any wheel to let ABS system work. It does on wet or icy road though. The pedal goes half-way to the floor just to close the gap between front brake pads and the rotors surface. When I was bleeding ABS and brake cylinders I noticed that front calipers do not retract if the bleeder is open. Master cylinder "sucks" the fluid back when the pedal is released. Bubbles inside the bleeder tube rush back to the cylinder when my helper releases the pedal. Vehicle was doing it all its life . The stopping distance is not too bad and the vehicle is close to its retirement. But it is interesting to know where is that valve that supposed to let "fresh" fluid into the calipers when the pedal retracts. is it in Master cylinder or somewhere in ABS? Now the system behaves as two syringes connected by a tube in the School project "excavator".

  • Vincent Competello
    Vincent Competello Apr 20, 2014

    If it doesn\'t skid on dry pavement and still reasonably stops the vehicle, that\'s how ABS works. The master cylinder does not suck fluid back into it when brakes are released. It merely releases the pressure. There is no valve to make fresh fluid go into the calipers in fact as the brake pads wear the fluid level in the master cylinder will drop due to it now being in the caliper because the piston is further out. The brake pads are constantly in contact with the rotor even when the brakes are not applied. The claliper pistons never retract. You can go one thinking what you\'re thinking about the brake system or you can try to understand this concept I am explaining to you. My way is backed by 40 years in the business. The person(s) that explained the other way I\' sure has less if any.

  • 09escape
    09escape Apr 20, 2014

    Thanks Vincent. It is all correct what you say. But I am sure that from time to time you see abnormalities that happen really rarely and you did see ar even never heard off. Those that happen 1 in 100,000 cases. Pistons in my vehocle front calipers do retract, I can insert a couple layers of a regular printer paper in the gap and I see a light in the gap if i look through and keep a light source on opposide side. I understand that the master cylinder must have some feature working as one way valve. For an example its piston may have a sort of a rubber cup that seals itself on the way down but it lets the fluid into the 'chamber' when the pedal goes up. My guess is that maybe the mastr cylinder bore is defective: it is conical instead of cylindrical and the "fresh" fluid does not go into until the master cylinder piston retracts half way up. What is your opinion, can it be viable idea, that the master cylinder is defective? If so, is it difficult to replace? The most complicated repair I did before was the GM 3.8L intake gasket replacement. Someone told me that rubber boots around caliper pistons may retract but I am sure it is not the case. With all new rotors and new (thick) pads installed it happens anyway, a paper goes into the gap. Of course after pumping the breaks. I appreciate your comment!

  • Vincent Competello
    Vincent Competello Apr 20, 2014

    Okay, let's get technical. First of all, the piston does not retract and the fluid does not cycle in any way. The master's bore is symmetrical not conical. The reason the piston give you clearance is that the pressure is released, the atmospheric pressure of. 14.7#s give or take equalizes. If you measure with a suitable tool other than paper, the distance of travel of the piston from the caliper, not the rotor, you will see that the piston's movement in relation to the caliper is minuscule. Everything that you say is a problem is not symptomatic to any brake failure.

  • 09escape
    09escape Apr 21, 2014

    Hi Vincent. Your description is how normal system works. It is not the case. The brake pedal touches the floor diring the emergency braking and the emergency stopping distance is twice longer than on my another car. Bleeding does not help and new rotors/calipers do not help. What solution you would suggest?

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How to retract brake caliper piston?


Hi, if this is a front caliper that is still on the rotor, I pry between the rotor and rear brake pad to push the piston in. I usually have to pull on the caliper a bit to get it retracted enough to get a screwdriver in between. If the caliper is already off the rotor, I leave the old inside pad on the piston and put a large c-clamp over the caliper to push on the pad and retract the piston. If this is a rear disk caliper or if you have any questions, please reply.

Jul 31, 2011 | 2004 Buick LeSabre

1 Answer

How can I change the rotors and brakes on a 2006 Cadillac?


Front brake
Step 1: Identify Front Disc Brake Components
brake_pads_rotor.jpg
Front Wheel Drive Brake Assembly
Most front disc brake components include: brake rotor, brake pads, brake caliper, caliper mount and brake flex hose. Brake service usual occurs between 20,000 and 40,000 miles depending on driver habits, road conditions and brake pad/ rotor materials used.
Step 2: Remove Brake Caliper to Replace Pads
brake_pad_set.jpg
Removing Brake Caliper Mounting Bolts
Locate primary caliper mounting bolts; apply wrench pressure counter-clockwise (When looking at the head of the bolt) to remove the bolts, upper and lower. Make sure the bolt threads are in good shape and replace if necessary.
Step 3: Remove Front Brake Caliper
remove_brake_caliper.jpg
Remove Front Brake Caliper
After removing the primary caliper mounting bolts lift the brake caliper off of the rotor and then tie or secure to the side, being careful not to bend or kink the brake caliper flex hose. Thoroughly inspect brake caliper and brake hoses for leakage, cracks or chaffing and replace as needed. Next remove the brake pads (If not mounted in the caliper) and secondary caliper mounting bolts. Notice how great protective gloves work, most technicians use them on the job today.
Step 4: Remove Brake Pads
remove_brake_pads.jpg
Remove Front Brake Pads
Once the brake pads have been removed, make sure if there is anti rattle hardware to transfer to the new brake pads. Some brake pad manufacturers will include the proper lube (Caliper slides) and anti-rattle hardware to ensure proper performance of their product.
Step 5: Remove Caliper Mount
remove_brake_pads_holder.jpg
Remove Caliper Mount Bracket
Finish removing secondary caliper mount bolts and remove caliper mount. Note: clean and lube caliper slides and pad friction surfaces of all foreign material or build-up.
Step 6: Remove Brake Rotor
brake_rotor.jpg
Remove Brake Rotor
With the caliper mount out of the way you can now remove the brake rotor. Sometimes it can get stuck so you may need to tap it with a hammer or use penetrating oil to free it up. Some manufacturers use small screws to hold the rotor on as well. Clean and inspect wheel studs, replace if any are damaged. Also clean bearing hub rotor mount surface to ensure the proper mounting of the new brake rotor. Inspect the ABS sensor wheel for cracks or damage and replace as needed.
Step 7: Depressing the Brake Caliper
compress_caliper.jpg
Resetting Brake Caliper
To install the new brake pads you must retract the brake caliper piston. Remove the master cylinder lid or open the brake caliper bleeder screw to allow excess brake fluid to be released if necessary. Install C clamp tool and gently tighten clamp until caliper piston is fully depressed. Note: use old brake pad to protect the caliper piston. Close the bleeders once the piston is retracted completely
Step 8: Installing New Brake Rotor
new_brake_rotor.jpg
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Install new brake rotor, the new rotor is manufactured with a protective film over the rotor to keep it from rusting, remove protective film with brake cleaner before installing; also after the brake job is complete you may experience a small amount of smoke from the rotor when first used. This is normal and will go away after the first couple of uses.
Step 9: Installing New Front Brake Pads
new_brake_pads.jpg
Installing New Brake Pads
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front_brake_rotor_pads.jpg
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Dec 18, 2010 | 2006 Cadillac STS

1 Answer

I need instructions on how to remove the rotors and replace the front brake pads on a 2004 mazda 6.


Instructions Things You'll Need:
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  • Jack stand(s)
  • Wheel chock
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  • DOT 3 brake fluid
  • Flathead screwdriver
  • 1/2-inch drive breaking bar
  • 1/2-inch drive socket set (up to 21 mm)
  • 1/2-inch drive ratchet
  • 1/2-inch drive adjustable torque wrench (recommended)
  • Impact screwdriver with Phillips head bit
  • Hammer
  • Bungee cord
  • C-clamp
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  • Shop rag(s)
    How to Replace Front Rotors on a Mazda6
  1. Step 1 Park the Mazda6 on a flat paved surface. Apply the parking brake and release the hood latch. Place a wheel chock behind one of the rear tires and open the hood. **** out half the fluid from the master cylinder reservoir using the turkey baster and discard. Replace the master cylinder cap securely.
  2. Step 2 Break the lug nuts loose on the front tire, using the breaking bar and a 21-mm socket. Raise the left quarter panel first with the floor jack and place the jack stand under the left front frame rail. You can lift the right side too or just do one side at a time. Remove the lug nuts and the wheel when elevated.
  3. Step 3 Pry the two plastic caliper slide bolt covers off with the flathead screwdriver and remove the caliper slide bolts with the ratchet and a socket. Pry the caliper off the pads and rotor with the screwdriver and support it to the coil spring with the bungee cord so it does not dangle by the brake hose. Compress the piston of the caliper inward using the C-clamp until the piston bottoms out in the caliper casing.
  4. Step 4 Remove the pads from the caliper anchor by prying them out gently with the screwdriver. Be sure to memorize how they were positioned in the anchor so you can replace them the same way in the event you're not replacing the pads as well. Remove the caliper anchor bolts using the ratchet and a socket. They're going to be extremely tight, so be prepared. Remove the caliper anchor.
  5. Step 5 Locate the retaining screw on the hub face of the rotor. Use the impact screwdriver in the reverse position with a Phillips head bit and strike the end of the screwdriver with the hammer. Remove the screw. Remove the rotor. If it is stubbornly stuck to the hub, strike it a few times with force on the plated fins of the rotor.
  6. Step 6 Spray the new rotor with brake clean and be generous to clean off the oil coating that new rotors have on them so they will not rust from condensation in the air while they were in storage. Clean both sides and wipe dry with a shop rag. Place the new rotor on the hub and make sure to line up the retaining screw hole in the rotor to the hub. Replace and tighten the retaining screw.
  7. Step 7 Replace the caliper anchor and bolts and tighten tightly. Replace the pads into the caliper anchor in the same manner you removed them. Replace the caliper over the pads and rotor and replace and tighten the caliper slide bolts. Replace the plastic covers.
  8. Step 8 Replace the wheel and lug nuts and tighten the lug nuts so they are flush. Lower the Mazda6 and torque the lug nuts alternately with the torque wrench, set at 80 foot-pounds and the 21-mm socket. If you raised both sides of the front axle, wait until you've replaced the right side rotor, otherwise repeat Step 2 through Step 8 for the right side.
  9. Step 9 Pump the foot brake pedal until it feels normal to restore the hydraulic pressure back to the compressed caliper pistons. Release the parking brake.
  10. Step 10 Check and add new DOT 3 brake fluid to the master cylinder and replace the cap securely. Close the hood. Remove the wheel chock and test drive

May 28, 2010 | 2004 Mazda 6

1 Answer

Need help changing brake pads and routers on 2003


Remove brake fluid from the master cylinder brake fluid reservoir until the reservoir is approximately 1/2 full. Discard the removed fluid.
  1. Raise and safely support the front of the vehicle. Remove the front wheels.
    1. Remove or disconnect the following:
    2. Front brake caliper guide pin bolts
    • Brake caliper by slowly sliding it up and off the adapter and brake rotor. Support the caliper out of the way with a strong piece of wire. Do not let the caliper hang by the brake hose or damage to the brake hose will result.
    1. If necessary, compress the caliper piston into the bore using a C-clamp. Insert a suitable piece of wood between the C-clamp and caliper piston to protect the piston.
    2. Outboard disc brake pad from the caliper by prying the brake pad retaining clip over the raised area on the caliper. Slide the brake pad down and off the caliper.
    • Inboard disc brake pad from the caliper by pulling the brake pad away from the caliper piston until the retaining clip on the pad is free from the caliper piston cavity
  • To install:
    1. Be sure the caliper piston has been completely retracted into the piston bore of the caliper assembly. This is required when installing the brake caliper equipped with new brake pads.
    2. If equipped, remove the protective paper from the noise suppression gaskets on the new disc brake pads.
    3. Install or connect the following:
      • New inboard disc brake pad into the caliper piston by pressing the pad firmly into the cavity of the caliper piston. Be sure the new inboard brake pad is seated squarely against the face of the brake caliper piston.
      • Outboard disc brake pad by sliding it onto the caliper assembly
      • Brake caliper assembly over the brake rotor and onto the steering knuckle adapter
      • Caliper guide pin bolts and torque to: 35 ft. lbs. (47 Nm) on 2002–04 models or 26 ft. lbs. (35 Nm) on 2005 models
      • Front. Apply the brake pedal several times until a firm pedal is obtained.
    4. Check the fluid level in the master cylinder and add fluid as necessary. Road-test the vehicle.

    For the rotors:

    1. Remove brake fluid from the master cylinder brake fluid reservoir until the reservoir is approximately 1/2 full. Discard the removed fluid.
    2. Raise and safely support the front of the vehicle. Remove the front wheels.
    1. Remove or disconnect the following:
    2. Front brake caliper guide pin bolts
    • Brake caliper by slowly sliding it up and off the adapter and brake rotor. Support the caliper out of the way with a strong piece of wire. Do not let the caliper hang by the brake hose or damage to the brake hose will result.
    1. If necessary, compress the caliper piston into the bore using a C-clamp. Insert a suitable piece of wood between the C-clamp and caliper piston to protect the piston.
    2. Outboard disc brake pad from the caliper by prying the brake pad retaining clip over the raised area on the caliper. Slide the brake pad down and off the caliper.
    • Inboard disc brake pad from the caliper by pulling the brake pad away from the caliper piston until the retaining clip on the pad is free from the caliper piston cavity
  • To install:
    1. Be sure the caliper piston has been completely retracted into the piston bore of the caliper assembly. This is required when installing the brake caliper equipped with new brake pads.
    2. If equipped, remove the protective paper from the noise suppression gaskets on the new disc brake pads.
    3. Install or connect the following:
      • New inboard disc brake pad into the caliper piston by pressing the pad firmly into the cavity of the caliper piston. Be sure the new inboard brake pad is seated squarely against the face of the brake caliper piston.
      • Outboard disc brake pad by sliding it onto the caliper assembly
      • Brake caliper assembly over the brake rotor and onto the steering knuckle adapter
      • Caliper guide pin bolts and torque to: 35 ft. lbs. (47 Nm) on 2002–04 models or 26 ft. lbs. (35 Nm) on 2005 models
      • Front. Apply the brake pedal several times until a firm pedal is obtained.
    4. Check the fluid level in the master cylinder and add fluid as necessary. Road-test the vehicle.

    May 28, 2010 | 2003 Chrysler Town & Country

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    1. did you bleed the system?
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    How to install front brake rotors for 2004 odyssy?


    1. remove 2 bolts holding caliper on (either 12 or 14 mm)
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    3. remove the 2 phillips head bolt holding the rotor on
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    Feb 20, 2010 | 2004 Honda Odyssey

    1 Answer

    How do you replace the front rotors on an 1999 Chevy express van 1500?


    REMEMBER TO REPLACE THE PADS AS WELL, NO USED PADS ON NEW ROTORS.

    Raise the vehicle and support on jack stands. Remove the wheels. Place the drip pan under the caliper. Loosen the 10 mm bleeder screw on the top of the caliper.
  • Step 2 Spread the brake pads apart with the common screwdriver. Place the screwdriver in the slot in the center of the caliper where the pads can be seen. With the nose of the screwdriver, pry between the rotor and the pad and pull the caliper outward toward you. The piston is being depressed into its housing as the caliper is pulled out. When the caliper comes to its limit outward, push the caliper back away from you and insert the screwdriver into the inside pad between the pad and the rotor. Once again pull the screwdriver toward you until the caliper piston is compressed into its bore.
  • Step 3 Tighten the 10 mm bleeder screw. Remove the caliper and support it where it is not hanging on the brake hose. Letting the caliper hang on the brake hose will damage the hose and cause brake failure.
  • Step 4 Remove the caliper support if it interferes with the removal of the rotor. Some vehicles don't require the removal of the support. Remove the rotor by pulling it off. If it is stuck, hit it with a hammer a few times between the studs.
  • Step 5 Install the caliper support and caliper in the reverse order they were taken off. Install the wheels and let the vehicle down. Check the brake fluid and fill as necessary to the proper level.
  • Step 6 Start the vehicle and pump the brakes very slowly until you have a high pedal. Remember that by expanding the calipers they have to re-adjust. You will not have any braking when you first start the car. Do not try to move the car until you have pumped the brake pedal sufficiently to feel a firm pedal.
    Rear-Wheel-Drive Vehicles
  • Step 1 Raise the vehicle and support on jack stands. Remove the wheels. Place the drip pan under the caliper. Loosen the 10 mm bleeder screw on the top of the caliper.
  • Step 2 Spread the brake pads apart with the common screwdriver. Place the screwdriver in the slot in the center of the caliper where the pads can be seen. With the nose of the screwdriver, pry between the rotor and the pad and pull the caliper outward toward you. The piston is being depressed into its housing as the caliper is pulled out. When the caliper comes to its limit outward, push the caliper back away from you and insert the screwdriver into the inside pad between the pad and the rotor. Once again, pull the screwdriver toward you until the caliper piston is compressed into its bore.
  • Step 3 Tighten the 10 mm bleeder screw. Remove the caliper and support it where it is not hanging on the brake hose. Letting the caliper hang on the brake hose will damage the hose and cause brake failure.
  • Step 4 Remove the bearing cap in the center of the rotor. Remove the cotter pin. Remove the large nut that retains the bearings and rotor. Wobble the rotor with your hands and the front bearing will come out.
  • Step 5 Reinstall the spindle nut with just a few threads. Grabbing the rotor with both hands, pull the rotor off with slight down pressure and with a quick ****. The spindle nut will grab the rear bearing and seal as you pull the rotor off and come out at the same time.
  • Step 6 Install the bearings into the new rotor. Grease the bearings first and install the rear large bearing then install the grease seal with the hammer. Install the rotor on the spindle and insert the front small bearing followed by the large washer and the retaining nut.
  • Step 7 Tighten the retaining nut just until there is no longer any freeplay then tighten an additional 90 degrees. Do not over tighten the retaining nut as it will not allow the bearings to expand and they will wear out rapidly. Install the cotter pin.
  • Step 8 Install the caliper support and caliper in the reverse order they were taken off. Install the wheels and let the vehicle down. Check the brake fluid and fill as necessary to the proper level.
  • Step 9 Start the vehicle and pump the brakes very slowly until you have a high pedal. Remember that by expanding the calipers they have to re-adjust. You will not have any braking when you first start the car. Do not try to move the car until you have pumped the brake pedal sufficiently to feel a firm pedal
  • Nov 11, 2009 | 1999 Chevrolet Silverado 1500

    2 Answers

    2001 brake pad replacement 2001 nissan quest


    The hard part is pressing the caliper piston abck into the caliper so you can get the new, thicker pads over the rotor. A large C Clamp works best.

    SECTION 206-03: Front Disc Brake 2001 Villager Workshop Manual
    REMOVAL AND INSTALLATION Pads —Front Disc Brake Removal
    1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 .
    1. Remove the front disc brake caliper bolts. torx bit. T20?
    1. Support the front disc brake caliper from the front strut and spring assembly using mechanics wire.
    1. Remove the front disc brake pads.
      1. Remove the outboard front disc brake pad.
      1. Remove the inboard front disc brake pad.
    Installation
    1. s1v~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Make sure the master cylinder reservoir does not overfill and spill brake fluid while retracting the front disc brake caliper piston.
      NOTE: It is necessary to fully retract the front disc brake caliper piston in the bore before installing the front disc brake pads.
      Install the front disc brake pads.
      1. Install the inboard front disc brake pad.
      1. Install the outboard front disc brake pad.
    Caution. The outer pads are left and right. put left on driver side.
    1. Position the front disc brake caliper on the front-wheel knuckle and install the brake caliper pin bolts.
    1. s1v~us~en~file=ani_caut.gif~gen~ref.gif WARNING: It is necessary to depress the brake pedal several times to position the front disc brake caliper piston before driving the vehicle.

    Apr 23, 2009 | 2001 Nissan Quest

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