Front Brake Disks Removal

[Archie]

In retrospect, I should've done this when I changed the pads a couple of weeks ago. The new pads won't fully bed down because of the lip on the rotor disks.

Anyway, once the caliper is off, how do I remove the pad carriers in order to get the rotor disk off?

Oh and any tips on how to get the pads past the lip when removing the caliper assembly?

Thanks.

[topher]

With the brake fluid reservoir cap removed, you can lever the pistons back into the caliper using a big screwdriver pressing against the disk to get a bit more clearance when removing the caliper.

The carrier bolts are a bit of a b@stard because they're torqued right up and a bit of a git to get to.. not to mention its a hex bolt. I actually have broken 3 in total 1/4 inch socket reducers and bent several heavy duty hex keys while trying to remove this bolts. Best way I found was to use the correct size hex bit from a socket set, but using a hefty 8mm spanner with an extension to crack the bolts. With a bit of twisting and hammer persuasion you should be able to get the pads in the caliper over the disk lip. Last thing in your way is the disk locating screw, although i've never seen one on a mk4 that doesn't come out first try.

[Archie]

Thanks - what size hex key do I need to remove the carrier bolts and how many of them are there?

[topher]

Two bolts, one top one bottom. Can't remember the size, I'm one of those people that just looks at the bolt and grabs a handful of tools from the chest hoping one of them will fit

[Archie]

Thanks, Topher. One of the easiest jobs I've done - only took 50min to do both sides. The pad carriers didn't need to come off to remove the rotor disk, in fact. VW must've changed the design for the FSIII caliper. All you need to do is remove the caliper assembly and unscrew the rotor (single locating screw). Wonder how much I saved doing it meself......

[jbob]

If you do ever need to take the carrier off then its an 8mm key 

[Ivor Mk4 Turbo]

If you do ever need to take the carrier off then its an 8mm key 

It's a 7mm hex!!! 

ps  & I've also broke a 1/4" drive ratchet & 3/8" > 1/4" reducer trying to undo the bloody things, LOL!!!