[200q20v] Re: Need some advice with rear caliper

[Kneale Brownson]

I took one of my old 200q20v rear calipers apart after I bought new ones to 
solve the half-a-year-long problem I had with the caliper hanging up 
despite all the routine services.   There is an internal C-clip at the base 
of the rod the piston screws onto that, if removed, permits removal of the 
threaded rod.  Beneath that you'll find a small peanut-like rod that fits 
into a cavity machined in the rod to which the parking brake activation 
lever is afixed.  You need to get the peanut out in order to remove the 
parking brake activation lever and its rod.  If the internals there are 
rusty, you probably need a new rubber seal that goes around the parking 
brake activation lever rod where it fits into the caliper body.  You'll 
also need to clean up the rust in the rod and the cavity part of it, as 
well as in the housing in the caliper.  A 5Ktq caliper I took apart to try 
to figure out how to get the 200's caliper apart had a very rusty 
chamber.  That car's parking cable had been cut off years before.  My 200 
didn't have any rust on the peanut/parking brake activator rod area, and 
the parking brake lever moved relatively freely, but the brake piston 
didn't draw back into its cylinder.  The inside of that cylinder had some 
small rust spots in several locations, and I suspect that it's that rust 
that kept the caliper from working properly.



At 09:33 AM 02/26/2001 -0800, Bernie Benz wrote:

>I have never had to remove the parking brake piston advance screw from the
>caliper, so don't know if it is possible.  But, with the piston out of the
>caliper and everything cleaned up, one can work the cam to be sure that it
>is free and easily returned by the return spring, after adding external
>lube.  I would not attempt to remove the cam and advance screw just for fun,
>unless they could not be freed by the above method.  If this internal
>cleaning of the caliper does not free up the PB release problem, more likely
>it is in the cable system.
>
>Bernie
>
> > From: Peter Schulz <peschulz at cisco.com>
> > Date: Mon, 26 Feb 2001 10:44:25 -0500
> > To: cahki at lav.Boehringer-Ingelheim.com
> > Cc: b.m.benz at prodigy.net
> > Subject: Re: Need some advise with rear galiper
> >
> > At 03:07 PM 2/23/2001 -0500, you wrote:
> >>
> >> Dear Peter C. Schulz,
> >>
> >> I saw you posted a message on how to fix the VW Rear Caliper sticking  in
> >> web page 20v.org/20v/brakprob.
> >> My rear Caliper is sticking, the shaft axle is rusted and I want to 
> take it
> >> out to remove the rust.
> >> I take out the piston but I still can take the shaft out. Do you have any
> >> idea how to take(remove) the shaft out?
> >>
> >> I would appreciate greatly if you could help me out about this matter.
> >> Claude
> >
> > Claude:
> >
> > Based upon your description, I cannot tell whether you are having an issue
> > with the caliper guide pins sticking, or the parking brake.
> >
> > If the caliper guide pins are sticking, you need to remove them from the
> > caliper, carefully remove the rubber boots, and polish the pins on a bench
> > grinder/polisher.  If they are too rusted, you may need to replace them.
> >
> > If the issues is tied to the parking brake, I removed the cable on the cam
> > which connects to shaft which is indexed to the caliper piston, I turned
> > the piston all of the way into the caliper, then used a screwdriver to help
> > pry the shaft/cam away from the caliper body -about 1 -1.5 cm.  I then
> > polished the shaft with some emory (sand paper) sprayed it liberally with
> > rust remover and let it dry.  Before putting it back to together, I applied
> > heavy duty brake grease to the shaft before working the cam back and forth
> > to its limits and reinstalling the parking brake cable.
> >
> > I've included Bernie Benz in this email, because he has taken this one step
> > further by completely rebuilding his brake calipers, therefore he has a
> > much better understanding of the internal workings of the caliper.  Bernie,
> > can you comment?
> >
> > Hope this helps!
> >
> >
> > Peter Schulz
> > 1990 CQ
> > 1991 200 20v TQW
> > Chelmsford, MA USA
> > peschulz at cisco.com
> >
>
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