Rear brake upgrades for Golf MK1/2/3

[jayjay]

This is stolen from Scottish VAG from MUSHY 16V. looks pretty good to me.

* The polo stub axle is from 1995 to early 2002 ie 6n, also seen on Seat Ibizas form 1998 to 2002
* It tends to be the 16v and diesel Polos that have rear disk brakes
* The complete assembly can used but if you use the polo calipers you will need to get flexy pipes with the banjo
* There are two sizes of calipers: 34mm and 38mm
* Both sizes have been listed for the mk2 in the past, and Mk4 golf has 38mm ones
* You will just have to see what is already fitted and use the same size or you may need to reset the brake bias compensator
* Mk4 golf calipers will fit but Mk4 carriers wont (same as if you were fitting Mk4 calipers to a Mk2/3 golf)
* All mk2 and mk3 and polo carriers will fit

Discs and back plate


Polo caliper


Hear is a list of part numbers used:

right side
stub axle =6n0501118
hub complete with nut and cover and ABS ring = 6x0598477
splash shield = 6n06 156 612
brake disc = 6n0 616 601a
bolt stub axle to beam =n90758901 (4 of per side) M10x30
bolt for brake carrier =n90740301 (2 of per side) M10x1.25x30

left side
stub axle =6n0501117
hub complete with nut and cover and ABS ring = 6x0598477
splash shield = 6n06 156 611
brake disc = 6n0 616 601a
bolt stub axle to beam =n90758901 (4 of per side) M10x30
bolt for brake carrier =n90740301 (2 of per side) M10x1.25x30

With all the old stub axle removed you should be left with this.

If you have a mk1 at this stage you will have to grind the bottom rear corner to let the stub axle sit flat

It is best to clean the axle threads out with a M10 tap since the Polo bolts are a bit longer



New stub axle and stone guard


ones the stub axle face is cleaned up you can fit the axle and back plate
and torque the four bolts to 60 nm or 44 lbf ft


then you can fit the hub new hubs will be pre-greased but i tend work some grease
in to the bearing then torque the self-locking 12-point nut to 175 nm or 129 lbf ft
then fit the cap don't over fill with grease or the cap will blow off




Then check the hub face is clean and flat and fit the brake disk and tighten the screw



Fit the carrier and torque to 65 nm or 48 lbf ft



Then fit the pads and reset the pad clearance on the caliper and fit bolts and torque to 35 nm or 26 lbf ft

Refit the hand brake cable and adjust

Fit wheels and torque wheel nuts to 110nm or 81 lbf ft with the car on the ground
then work the hand brake and pump the brakes

If you fitted new calipers you would obviously bleed them at this point



* this a list of cars that have the stub axle with the part no 6n0501117 and 6n0501118 fitted

* Polo/Derby 1995 , 2002
* Polo Classic/Variant 1997 , 2000
* Cordoba/Vario 1997 , 2002
* Ibiza 1997 ,2002

[black bob]

nice conversion done well

[Peter Jones]

Interesting conversion.
Is that a MK2 used as an example?
Whatever the car is, it looks like it had disc brakes to start with and this is an upgrade to larger discs.

For MK1s, MK 3 discs are an easier swap, I'm not sure of the availability of those Polo parts here.

For a MK1 you also need to find the right handbrake cables which can be a bit of a challenge as you need Scirocco ones.

Brake biasing can also be an issue and you need to use some sort of brake bias valve on a MK1 the limit the rears.

This is a MK3 Disc on a MK1.