Ok guys I know this is a pretty simple task, but I did it 2x today (02 DSG and 03 BLK) and had a few tips, and if anyone is thinking about having someone else do it. It’s a pretty simple task
Tools required
Sockets
10mm
13mm
15mm
18mm
21mm
and 27mm
Impact or large handle
Large C clamp
High temp bearing grease
Flat Head screwdriver
Needle nose pliers
Brake Cleaner
WD40
Hammer
Optional
New Wheel bearings or the tool to pack the grease in the bearings, the twin plastic circles (or your hands smell like bearing grease, like mine)
And new pads and rotors (at least have the rotors turned)
I used slotted, dimpled, zinc washed rotors
And Hawk HPS pads
Ok here we go; back first it’s much easier...
Jack and support truck
Take off wheels (loosen on ground if you have no impact)
Remove the 2 10mm bolts that are holding the caliper on, they aren’t super tight
Remove the caliper by lifting up and it comes out of its slot.
Remove the outer pad first with a flat head screwdriver releasing the pins and lift up.
Remove the inner pad, just pulls out.
Now put WD 40 on the center of the rotor
Next remove the brake rotor, nothing accept the center likes to rust into the rotor, i used a little impact calibration (hammer) and pulling on it... Hit in the middle of the rotor around the rusty axle part, and it will break free and yank it off.
Now put the new rotor on make sure it’s all the way on
Take your old pad, put it on the caliper side and take your C clamp and bottom out the piston, also watch the level of your brake fluid, its easier to turn if you take the top off your master cylinder reservoir.
Load the new pads in
Put the caliper on the rotor
Line up the 2 10mm bolts and tighten down, not too tight, it wasn’t that hard to get off.
Now the front.
Jack up the front and take off the wheels
The fronts have 4 bolts on each caliper.
Take off the 2 13mm (im 99.99% sure might be 15) 1st that will get the caliper off and you can pull that and put it out of the way, I put it on an extra jack stand, its connected via brake like, DO NOT let it hang
Then take off the caliper mounting bracket, that’s 18mm, 2 bolts, caliper bracket will come off
Now remove the dust cover from the wheel bearing with a hammer and a flathead screwdriver, be careful no to hammer too hard, just get in-between the hub and the cover, and pry it off
Now bend the cotter pin with needle nose pliers and pull off.
Remove the cotter pin retaining cover off
Remove the 27mm nut from the middle.
Remove the front wheel bearing by just starting to remove the rotor, the bearing and the retaining plate.
Put the 27mm back on and pull the rotor down and out at the same time. the rear bearing should hang up on the nut and off the rotor.
Time to pack the bearings, I chose the backyard style install, take bearing grease in your hand, and work it into the bearing by little by little putting the sides into grease and hit it on your hand, forcing the grease up to the top, you should do this till you see new grease on both inner and outer. Its fun.
Now take the back bearing, put it in the back of the new rotor
followed by the back retaining plate, and give it a careful hammer into place, don’t bend the back backing plate, just get it into place
Put the rotor into place on the truck on the spindle.
Install front bearing followed by retaining plate
Then the 27mm Nut, hand tight. Put about 15ft-LBS of tq on that bolt, not a lot. Then spin the new rotor freely, it should spin nice
then the coder pin retainer followed by the coder pin, and bend it back W needle nose.
Install dust shield with a hammer again, make sure its centered
Put on caliper bracket 18mm bolts, TIGHT, if you have an impact use it, turn the wheel so you have room.
Next put the pads on the rotor in the caliper bracket. The rattler goes on the outside, other pad on the inside.
Now take the C clamp and press in the pistons with your old pad, till their all the way in.
The caliper should slide over the new pads and right into the caliper bracket.
Now take the 13mm and put those 2 bolts in pretty tight, its a little tricky lining up the bolts, just take your time.
And then get the cover back on the master cylinder reservoir if you took it off.
Reinstall wheels
Pump the brakes before driving to make sure you have pedal pressure.
And you should be good to go.
The combo of the pads and rotors I got.. SWEET, nice feel great stopping, just sweet.
Ill post pics of the final product, I just gotta paint my calipers they look like crap now. it looks sweet.
I think thats about it
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