Tools Required for Replacing Discs and Pads in MK5 Golf
Please note, I preferably recommend the use of sockets for better joints and because they're stronger, although if you're short on equipment you can use allen keys, spanners. Although there is a chance you can damage your parts
7mm Allen Socket
Car Jack
Copper Grease
Wire Brush
Rags
Brake and Clutch Cleaner
Brake Fluid
Brake Rewind Kit / Tool
Screwdriver / Pry Bar
21mm Socket
T30 Torx Socket
Breaker Bar {optional}
Hammer {optional}
Data that may be useful
Caliper Make
Disc Size
Brake Pad Size
Comments
Part Numbers
Kelsey Hayes
Diameter 280.0 mm
Thickness 21.6 mm
Height 49.4 mm
Hub Hole (Diameter) 65.0 mm
L146.0 x H54.7 x D19.8
Don't know if these models are actually used. All the brakes I've done where made by Lucas/ATE so could be these are reserved for models with lower spec
BPS Website (below)
Disc = BPS6113
Pads = BPS2603
ATE
Diameter 288.0 mm
Thickness 24.9 mm
Height 49.7 mm
Hub Hole (Diameter) 65.0 mm
L156.5 x H71.4 x D20.3 (wheel side)
L155.2 x H66.0 x D20.3 (piston side)
Usually found on the GT TDI 140 Model
BPS Website (below)
Disc = BPS6114
Pads = BPS2818
Brakeworld
Disc = RS3780
Pads = JCP1641
Diameter 312.0 mm
Thickness 25.0 mm
Height 49.7 mm
Hub Hole (Diameter) 65.0 mm
Usually found on the GT TDI 170 Model
BPS Website (below)
Disc = BPS6265
Pads = BPS2818
I'm not 100% sure on the above measurements over which size is which pad (inner or outer), but you can't get them wrong on fitment.Just remember to fit the springs in the pistons and the ABS wire goes on the passenger side of the car (UK model) and you will have them fitted correctly
The equipment I purchased was made by Brakeworld so I have added the part numbers above that are relevant to that product specifically for the GT TDI 140 which has ATE calipers. However this is the link to buy from if you don't have a local autoparts store. I've used this site before and he's a very good person and is competitively priced - free plug to him...... [link removed now DEFUNCT]
Brake Disc and Pad Replacement Procedure
Open the bonnet and remove the brake fluid reservoir cap
Loosen the wheel nuts and jack up the car, then remove the wheels
Pop off the caliper carrier dust caps
Loosen the caliper carrier bolts with the 7mm allen key (one at top and one at bottom)
Remove the retaining clip on the brake caliper housing
Remove the brake caliper using a pry bar or screwdriver, lever it away from the discs and pads
Remove old pads (compare against new pads to make sure they're the right ones)
Loosen the 21mm caliper mounting bolts with a socket and remove
Using a T30 Torx remove the disc mounting screw and remove the disc (compare against the new disc to make sure it's right)
Using a wire brush thoroughly brush away at the metal on the hub, the caliper and the caliper carrier as any interference can affect brakes
Push the brake piston back into the housing (if it's stuck clamp off the flexi hose and open the bleed nipple) - if not, check out my brake rebuild guide. Providing you didn't open the bleed nipples you shouldn't need to bleed the brakes. If you opened them remember to close them when pistons go back
Spray the brake cleaner on the disc and wipe it down with rags then refit the new disc and tighten the T30 torx bolt to hold it on
Refit the brake caliper (removed in step 8) - remember to grease the bolts to aid removal in future
Put copper grease on the back of the brake pads (the part that connects against the caliper) - do the piston side first as it has a spring
Once you have put one brake pad on refit the caliper back to the hub - connect up the other brake pad
Place the caliper back over the brakes and insert the carrier pins (make sure you grease these too)
Refit the spring under tension
Refit the wheel, spin it to check for any problems - lower car and tighten nuts
Repeat for the passenger side, this has the ABS connector, take care not to damage on removal, procedure is the same as before
When finished, top up any brake fluid as required, refit cap and pump the brakes
Start the car and push brakes a couple of times to make sure you have pressure - if pressure is weak check everything make sure bleed nipples are closed, you have correctly topped up brake fluid and there are no leaks
REMEMBER TO PUMP UP THE BRAKES BEFORE YOU DRIVE!!!!!!!
Torque Settings
TBC when I obtain them - I usually nip the bolts tight on the caliper carrier then tighten a bit more. The hub bolts I tighten, tighten a bit more, then tighten. The hub torx I just nip up and tighten another 90 degress.