Front disc brakes

Resources:

Mk IV Build Manual


IMG 1580

The primary brake components (minus the rotor) are shown to the left.   The caliper bracket attaches to the spindle; the caliper to the caliper bracket.  The pad with the closer-spaced ‘pimples’ go farthest from the pistons.





The disc brakes consist of PBR two-piston calipers with 11” rotors.  The installation is relatively straightforward although neither PBE nor F5 provide assembly schematics.  The only puzzle was the attachment of the brake pad clips, which I detail below.  The general sequence of installation is this:

  •     Rotor attached to the hub and held in place with several hub nuts;
  •     Caliper attached to the caliper bracket using the caliper slide assembly:
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Install the brake pad (anti-vibration) clips on the caliper and caliper bracket.  There are three brackets: two are the same.  The bracket that is dissimilar goes in the center of the caliper:

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This is the caliper bracket and one of the brake clips showing the correct orientation.  The purpose of the brake clips is to reduce wear to the caliper from brake pad movement.




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The photo to the left shows the anti-rattle clip in place.




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The assembled brake housing with the brake pads in place.  The pads are put in place after the brake pad holder is slide on the caliper slides.



Notes:

  •     The caliper slides need to be lubricated with  a high T brake lubrication compound.  I used Sil-Glyde by AGS.
  •     The caliper slides are attached to the caliper using 5/16” steel bolts; I torqued them at 131 in. lbs.
  •     The calipers are marked with ‘L’ and ‘R’; be sure to place them on the correct side.  The valve for bleeding the brakes     needs to be pointing ‘up' (see photo).
  •     The brake assembly is attached to the spindle using a 12 mm bolt with a 12 pt.head.  The F5 assembly video states incorrectly that it is a 13 mm bolt.