VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 1 of 17

My Profile | Active Users | Help | Search | Google Search

You are logged in as Massboykie, Log out

VWvortex Forums Brakes Girling 54 rebuild/ mk3 upgrade

hookdub DIY: Girling 54 rebuild/ mk3 upgrade « » 6:49 PM 4-1

Member

Offline

Member Since
11-21-2003
141 posts

Bergen County
NJ
97 Golf TREK

(Can a moderator put a DIY in the title so it doesnt look like a question)
Here is a list of parts. I will go over this how to again to refine it but pics speek louder than words.

Caliper Guide Pin Boot Kit

Caliper Repair Kit
Bleeder screw with check valve
Brake clean.
DOT 4 ATE blue brake fluid
turkey baister

For a MK3 upgrade get a set of Corrado rotors. The calipers bolt up like they were made to fit.

Get the bleeder screws with the check valve. With this check valve you can bleed you brakes by youself without the tool.
The steps seem weird because I got a wrong rebuild kit the first time so I painted it then rebuilt it.

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 2 of 17

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 3 of 17

Wire wheel the heck out of it

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 4 of 17

for all the fans file & smooth the casting marks on the carier and calliper

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 5 of 17

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 6 of 17

I was carefull with poping out the piston. 40psi worked for me. Use a bunch of brake clean in and out.

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 7 of 17

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 8 of 17

Remone the o ring from the caliper with something softer than steel and be carefull not to scratch the walls. Replacing the oring is sim
piston and caliper wall with new brake fluid for assembly lube. Here is the tricky part I found it easy to slide the seal on the groove of
can be unfolded.You see how the seal is sitting, the side that seals with the caliper is sitting slid up from the piston. Now with the seal
arrange the piston in the calliper so you can seat the seal with the calliper while keeping it on the piston. It took me a while but it is th
destroy the seal. I pressed the piston in by hand with a little TLC. I HIGHLY sugest you slide the piston in and out using the air and wo
because I didn't get the seal right the first time even though it seemed ok until I cycled the piston.

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 9 of 17

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 10 of 17

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 11 of 17

make sure the bleeder screw is facing up when installed to make sure you didnt install them upside down

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 12 of 17

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 13 of 17

I didnt take pics of every step because my hands were dirty.

The slider pins, boots and the bleeder screws are easy enough.
Make sure to grease the slider pins, this will make sure you caliper dosent bind.
One thing, make sure to coat the o-rings and boot seals with brake fluid for a positive seal.
Last thing is to bleed the brakes. I used a turkey baister to remove old fluid from the master.
Once you start bleeding keep an eye on the master.
FYI, when/if painting the underside go lite. Putting too much paint will make the pads a tight fit.

Modified by hookdub at 8:30 PM 4-17-2007

(O*o)======(o*O)
..___..______ ..___..
..\xx\ \xxxx/ /xx/..

screwedrrado Re: DIY: Girling 54 rebuild/ mk3 upgrade (hookdub) » « » 7:44 PM 4-1
Member

Online

Member Since
3-13-2007
718 posts

SA Town Texas
Diesel Caddy

Nice writeup, Im sure your happy with the results, poorly lubricated caliper pins cause all kinds of drama, next time see if you can find
up your calipers with some powder coat, alot more durable than paint,

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 14 of 17

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 15 of 17

Semper Fidelis
4781 posts on my previous screen name screwedrado
Parting Rabbits, check the pics All A1/Corrado parts on photobucket
Email me click here

Dutchsider Re: DIY: Girling 54 rebuild/ mk3 upgrade (hookdub) » « » 8:22 PM 4-1
Member

Wow, great write up. I will be picking up a set of Girling 60s and hopefully doing this. Your efforts are appreciated by the Tex

Offline Quote, originally posted by fredjet99 »

Member Since put some penut butter on your key and jigggle it back and fourth in the ignition
4-26-2006
953 posts Quote, originally posted by Crobo »

Population i was drive down roads then i see ducks . .

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 16 of 17

increase PA
1995 Jetta GLX I'm looking for coilovers. IM me

I miss my 16v but love my VR6

http://www.myspace.com/dutchsider

eurotekms Re: DIY: Girling 54 rebuild/ mk3 upgrade (Dutchsider) » « » 8:44 PM 4-1
Member

Offline
real nice. been meaning to do this. where did you buy the rebuild kit?
Member Since
2-10-2002
1097 posts
2.8L VR6 11.5:1
Scottsdale AZ
1993 Jetta VR6

hookdub Re: DIY: Girling 54 rebuild/ mk3 upgrade (eurotekms) » « » 8:49 PM 4-1
Member

rockauto.com just dont get the cheep kit. I got the wrong pieces. I think the brand was twk.
Offline
Modified by hookdub at 8:52 PM 4-16-2007
Member Since
11-21-2003
141 posts
(O*o)======(o*O)
Bergen County ..___..______ ..___..
NJ ..\xx\ \xxxx/ /xx/..
97 Golf TREK

O2VW1.8T Re: DIY: Girling 54 rebuild/ mk3 upgrade (hookdub) » « » 5:26 PM 4-1
Member

Did u replace every hose for DOT 5 fluid

Offline

Member Since
7-8-2003
10840 posts DonR'The 1.8T Prodigy' Quick enough
///Pag-Parts!
boosted NC kineticmotorsport
All wheel drive
1.8T

hookdub Re: DIY: Girling 54 rebuild/ mk3 upgrade (O2VW1.8T) » « » 8:15 PM 4-1
Member

I didn' t use the dot 5, I used the ate blue dot 4 fluid. Sorry this post is a work in progress
Offline
Modified by hookdub at 8:22 PM 4-17-2007

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007
VWvortex Forums: Girling 54 rebuild/ mk3 upgrade Page 17 of 17

Member Since
11-21-2003
141 posts (O*o)======(o*O)
..___..______ ..___..
Bergen County ..\xx\ \xxxx/ /xx/..
NJ
97 Golf TREK

O2VW1.8T Re: DIY: Girling 54 rebuild/ mk3 upgrade (hookdub) » « » 8:47 PM 4-1
Member

Quote, originally posted by hookdub »

I didn' t use the dot 5, I used the ate blue dot 4 fluid. Sorry this post is a work in progress

Offline
Modified by hookdub at 8:22 PM 4-17-2007
Member Since
7-8-2003 yeah i was confused, cause it would be stupid to use dot 5 cause everything needs to be changed
10840 posts

boosted NC
All wheel drive
1.8T DonR'The 1.8T Prodigy' Quick enough
///Pag-Parts!
kineticmotorsport

» Return to Brakes Brakes Quick Reply

Investment Property
News Homes starting at $269,000 Branson's only private golf course
www.stonebridgenorth.com
Ads by Google

For advertising information Click Here

Powered by ZeroForum 2.1.2. ©2005 RelyNet, Inc.

http://forums.vwvortex.com/zerothread?id=3186789 4/17/2007