Question about 2007 Volkswagen Jetta 2.5 Sedan

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Left rear brake caliper on a 4 wheel disc has stuck and wore the pads down to the metal. I am not able to reseat the piston into the bore. I have tried rotating the piston cw and ccw with no luck. I have ordered a new caliper and would like to know if there are any hints on easy install. 2007 vw Jetta 2.5

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Unfortunately, you need a 'cylinder rewind tool.
That's what made it impossible to compress.
It's basically a 'vice', but it turns, and thus screws the cylinder in.
It's a specialised tool.

Posted on Jul 27, 2009

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1994 dodge 2500 diesel. Put remanfactored calipers and new hoses on the front of this truck. Now I have a soft pedal that if held fades to the floor. Thought the master cyl must have a leak in it. Replaced...


Hi,
sound as if you really do have a problem!
From your description I presume that you are confident in doing your own work?
The quickest way to check your system is to use brake hose clamps to isolate each section of the braking system. I would suggest that you rent or buy a set of the clamps.

Put the truck on axle stands and make sure it's safely secured. ]
If possible have an assistant to sit in the cab and depress the brake pedal on your instructions.
Place a brake hose clamp on both front brake hoses and the rear axle hose.
Depress the brake pedal firmly.
The pedal should have minimum movement, and be rock-solid and you should not be able to depress it further.
If the pedal does go down when you apply it, the likely reason is that the Brake Master Cyl is by-passing internally, ie, only one section is active.

You stated that the M/C had been replaced. so we shall presume that the brake pedal is rock hard.
Go to the rear brake hose clamp and release it. Instruct your assistant to depress the brake pedal. If the brake pedal moves a significant distance, then (a) your rear brake shoes require adjustment (b) rhere is a leaking brake cyl, (check for brake fluid in the drum) or (c) you have a "lazy' or a piston (s) which have siezed during a brake actuation. That problem will require removing the rear brake drums for further inspection. Not the problem? Then adjust the rear brakes if required, then depress the brake pedal again. The downward travel should now be noticeably reduced.

If all is well at the rear brakes. refit the brake hose clamp. Go to the passengers side front brake and have your assistant apply the footbrake. Pedal rockhard/minimun movement? Release the brake hose clamp whilst your assist has pressure on the pedal. spin the front wheel by hand, and note if (a) the brake pedal has excessive downward travel. (b) the brake pads are contacting the brake disc, (the wheel will cease rotating and you will hear the pads contact the disc.)

Pedal displays limited downward travel and pads contact disc? Refit the brake hose clamp and go to drivers side brake and follow the same procedure. If the pedal has excessive downward travel then you have found your inital problem.

If releasing both front brake hose clamps results in excessive brake pedal travel, then the problem will be easier to address if you deal with one side first, complete the resolution, test by using the brake hose clamps, then start / complete the other faulty brake.

Whichever side you start to work on, be methodical, boring as it sounds.
remove the road wheel, but before doing so, place a hand on the top and bottom of the tyre and rock the wheel away from you and check the bearing play. If memory serves me correctly, that year Dodge has the discs in one piece with the hub.

You have removed the wheel. Now, have your assistant turn the steering onto full right lock. Before continuing, I would like to remind you that the vehicle is up on axle stands and you have secured it safely, in order to conform with accepted safety parameters, correct?

The steering is now on full right lock and you can see both disc pads. Now, very carefully check the position of the caliper in relation to the disc pads. Is there and equal spacing on each side? Now, have your assistant release the brake pedal and very carefully observe the travel of the disc pad pistons. They should retract and the hub should turn freely by hand. A very light drag is allowed between disc pad and disc, but it should NOT be discernible when you rotate the hub by hand.

With no pressure on the brake pedal, and using an appropriate tool, attempt to have the caliper pistons retract into their cylinders / bores. Completed? Use caution as it is very easy to break / damage a disc by using undue force when retracting the pistons.

There is now an obvious gap between disc pads and disc (or rotor..sorry) Now, carefully check that the pad guide pins are not deformed and that the pads ride easily on them. if a pad jams when the brakes are applied, then, when the piston retracts, when force is removed from the brake pedal. There is an appreciable gap to close, upon the next application of the brakes!

Some types of disc pad retaining /guide pins are a tight fit, and it is very easy to tilt a pad when fitting the pins, causing the disc pad to fail to retract fully, and again, displayed by a brake pedal with excessive travel.

When the brake pedal is applied, the brake fluid has to fill the caliper piston bores, then exert pressure on the piston to force it against the disc pads, and they in turn are forced into contact with the disc. If the piston has to move an appreciable distance before contacting the disc pad, that takes more brake fluid to fill the bore of the piston, and the master cylinder piston has to travel further,resulting in a brake pedal that displays excessive travel .

I notice that you did not mention the type of effort or number of applications of the brake pedal which resulted in a firm pedal.

If you fitted replacement calipers, can I presume that you fitted new guide pins to the calipers?
Last but not least, (a) are they the correct calipers for the vehicle as regards piston bore size? The brake Master cyl will not be able to fill the bores of the calipers with enough fluid to drive the pistons out to apply the disc pads, if the bores are oversized. The pedal will also display excessive travel.
(b) If the brake master cyl is overfilled, when the brakes are applied, the master cyl will force fluid to the calipers, expand the caliper pistons, but will be unable to release the application to the pistons due to the fluid being unable to return to the master cyl as the allotted reservoir space has been filled with static fluid. When the brake pedal is depressed again, the Master cyl cannot service the caliper pistons on the first stroke as the pistons are locked at full stroke / travel in the bores, resulting in the brake pedal going to the floor, or giving that impression.
HOWEVER, that condition, if the vehicle is driven any distance, will result in the obvious odor of overheated disc brake pads, and the vehicle struggling to display any state of acceleration.
(c) Are they in fact the correct disc brake pads? It would be wise to remove a guide / retainer pin and check for free movement of the pad on the remaining pin. All ok, then refit the pin which you removed and test again. The pads have to be free to move on the pins, and thus align themselves with the face of the disc / rotor when the brakes are applied. Some people coat the pins with never-seeze or hi-temp grease when fitting them, others prefer them to be dry.

In closing, I would recommend that you check the full travel AND RETRACTION of the caliper pistons in their respective bores. It is not unknown for re-built / new parts to be defective.

It would be interesting to hear if any of the above proved to be beneficial in resolving your problem.

Jan 27, 2011 | 1994 Dodge Ram

1 Answer

Will I need a caliper reset tool kit to change the brakes on my 2007 toyota sienna or will a standard c-clamp do the job? And since it is an ABS system, I assume that brakes must be bled, correct?


Brake Pads Removal & Installation Front To Remove:
  1. Remove the front wheels. Front brake caliper (exploded view) toyota-09-00-5838.gif

  2. Loosen the caliper bleeder.
  3. Hold the slide pin; remove the 2 mounting bolts and remove the brake caliper from the support.
  4. Support the caliper.
  5. Open the brake bleeder. Press the caliper piston into the bore.
  6. Close the bleeder after the piston has reached the bottom of the caliper bore.
  7. Remove the brake pads, support plates, wear indicators and anti squeal shims.
  8. Remove the slide pins and bushings from the caliper support.
To Install:
  1. Lubricate the slide pins and bushings with brake grease.
  2. Install the bushing on the slide pin.
  3. Install the slide pin on the caliper support.
  4. Install the brake pad support plates on the caliper supports.
  5. Lubricate the anti squeal shims with brake grease.
  6. Install the anti squeal shims on the brake pads.
  7. Install the pad wear indicator facing upward and install the pads on the caliper support.
  8. Install the caliper on the support.
  9. Install the 2 mounting bolts, hold the slide pins and tighten 25 ft-lb (34 Nm).
  10. Fill the reservoir and bleed the brakes.
  11. Install the front wheels.
Rear To Remove:
  1. Remove the rear wheels.
  2. Loosen the caliper bleeder. Rear brake caliper (exploded view) toyota-09-00-5842.gif

  3. Hold the slide pin; remove the 2 mounting bolts and rear brake caliper assembly from the support.
  4. Support the caliper.
  5. Open the brake bleeder. Press the caliper piston into the bore.
  6. Close the bleeder after the piston has reached the bottom of the caliper bore.
  7. Remove the brake pads, support plates, and anti squeal shims.
  8. Remove the slide pins from the caliper support.
To Install:
  1. Lubricate the slide pins with brake grease.
  2. Install the slide pin on the caliper support.
  3. Install the brake pad support plates on the caliper supports.
  4. Lubricate the anti squeal shims with brake grease.
  5. Install the anti squeal shims on the brake pads.
  6. Install the rear pads on the caliper support.
  7. Install the rear caliper on the support.
  8. Install the 2 mounting bolts, hold the slide pins and tighten 25 ft-lb (34 Nm).
  9. Fill the reservoir and bleed the brakes.
  10. Install the front wheels.
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Sep 18, 2010 | 2007 Toyota Sienna

1 Answer

Have taken apart but cant get new or old pads back on now. not enough space and part that should move back to make space wont seems to be jammed or siezed. have tried letting out brake fluid but didnt...


  • To install: Front
  1. Compress the piston of the disc brake caliper.
  2. Install the brake pads and caliper assembly.
  3. Lubricate the guide pin. Tighten the guide pin to 16-23 ft. lbs. (22-31 Nm).
8267164.gif

REAR :
  1. Pull out the pad springs and then remove the pads and shims.

To install:

  1. Clean the piston end of the caliper body and the area around the pin holes. Be careful not to get oil on the rotor.
  2. Carefully turn the piston clockwise back into the caliper body (this can be done with a pair of needle nose pliers). Take care not to damage the piston boot.
  3. Coat the pad contact area on the mounting support with a silicone based grease.
A special tool is available to rotate the caliper piston

WARNING

Do not press the piston into the bore as performed on the front disc brakes. Due to the parking brake mechanism, the caliper piston must be turned into the bore.

WARNING

Do not press the piston into the bore as performed on the front disc brakes. Due to the parking brake mechanism, the caliper piston must be turned into the bore.
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Sep 15, 2010 | 1996 Nissan Maxima

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

    1 Answer

    2006 Kia Spectra 5 rear brake disc replacement


    One side,turns right,and push in slightly,and the other side turns left,to retract.

    Apr 20, 2010 | 2007 Kia Spectra5

    1 Answer

    I want to repair the brakes on a 1999 Chrysler Town & Country minivan - Would like instructions and a picture/diagram, if possible.


    Chrysler Caravan/Voyager/Town and Country 1996-1999

    CAUTION
    Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.
    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 of the vehicle. Remove the wheels.
    3. Remove the brake caliper assembly that requires brake pad replacement.
    4. 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.
    5. 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.
    6. Remove the 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.
    7. Remove the 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 the 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.
    4. Install the outboard disc brake pad by sliding it onto the caliper assembly.
    5. Install the brake caliper assembly.
    6. Install the wheels and lug nuts. Torque the lug nuts, in a star pattern sequence, to 95 ft. lbs. (129 Nm). Apply the brake pedal several times until a firm pedal is obtained.
    7. Check the fluid level in the master cylinder and add fluid as necessary. Road test the vehicle.
    You can find more details and images about this repalcement in autozone.com (free register).

    Hope helped with this. Good luck (remember rated this help).

    Nov 20, 2009 | 1999 Chrysler Town & Country

    1 Answer

    How can i change the rear brakes pads?


    1.Remove the cap from the brake fluid reservoir

    2.Loosen the wheel nuts then raise the vehicle and remove wheel

    3.Push the piston back into the bore to provide room for the new brake pads.A C-clamp can be used to accomplish this As the piston is depressed to the bottom of the caliper bore the fluid in the master cylinder will rise.Make sure is doesnt overflow.If necessary drain off some of the fluid. 4.Before removing anything,spray the disc,and brake pads with brake system cleaner dont use compressed air 5.remove the caliper mounting bolt,the banjo fitting for the brake hose shouldnt be disconnected unless you are removing the caliper or hose replacement

    6.Swing the caliper up and secure the caliper up towards the spring with a piece of wire then remove the lower and upper anti-rattle springs.Remove the outer brake pad and shim then remove the inner brake pad ans shim(s)

    7.Remove and inspect the upper and lower pad retainer clips,the pad retainer clips should fit snugly in the caliper mounting bracket;if they dont,replace them.Apply thin film of high-temperature grease to the retainer

    8.Apply anti-squel compound to the back of pads install the new inner pad and shim(s) make sure the "ears" on the upper and lower ends of the pad are fully engaged with their respective grooves and the pad retainer clips

    9.Install the new outer pad and shim if new pad has no shim take the old shimoff the old pad and install it on the new outer pad.Install the upper and lower anti-rattle springs

    10.Clean off the caliper pin and coat it with high-temperature grease.Lubricate the lower caliper pin with grease too thenswing the caliper down over the disc and new pads (if the piston hits the inner pad depress the piston further into the caliper bore with your c-clamp

    11.Install the mounting bolt and tighten it to the torque specifications (44-63) 99 and earlier models (51-55)00 and later models
    12.Put the wheel back on and tighten lug nuts

    Oct 05, 2009 | 1998 Hyundai Elantra

    1 Answer

    Rear disc brakes


    Raise the rear of the truck off the ground using jacks. Support the vehicle on both sides with jack stands to prevent it from tipping over. 
    Loosen the lug nuts on the wheels and remove the wheels assembly and set aside, face up, to prevent damage.
    Disconnect the caliper bolts and remove the brake caliper. Use mechanic's wire to fasten the caliper to your truck's side rail. Take out the outer disc brake pads followed by the inner pads.
    Compress the brake piston into the caliper bore using a C-clamp. Replace the inner brake pads followed by the outer brake pads. Remove the C-clamp.
    Remove the mechanic's wire from the caliper. Lay the caliper over the pads, fasten it down and tighten the caliper bolts with the torque wrench to 26 ft. lb.
    Replace the wheels and lower the vehicle to the ground. Bleed the brakes if necessary and check the brake performance during a short test drive.
    Good luck and hope this helps.


    May 05, 2009 | 2004 Ford F250

    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

    1 Answer

    2002 tahoe breaks lock up during driving


    It sounds like the rear calipers are bad. Raise the rear wheels and see if you can turn the tires. If you can't, open the bleeder. If you still can't replace the caliper. If you can turn the wheel after you open the bleeder, replace the brake hose to that wheel.

    Apr 12, 2009 | 2000 Chevrolet Silverado 1500

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