How to change front brake caliper on VW Fox Hatchback (5Z1, 5Z3, 5Z4) – replacement guide
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Recommended replacement interval for the part category Brake caliper : 100000km
Important!
This replacement procedure can be used for:
VW Fox Hatchback (5Z1, 5Z3, 5Z4) 1.4,
VW Fox Hatchback (5Z1, 5Z3, 5Z4) 1.4 TDI,
VW Fox Hatchback (5Z1, 5Z3, 5Z4) 1.2
…
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The steps may slightly vary depending on the car design.
This video shows the replacement procedure of a similar car part on another vehicle
All the parts you need to replace – Brake Calipers for Fox Hatchback (5Z1, 5Z3, 5Z4) and other VW models
Replacement: brake caliper – VW FOX (5Z1, 5Z3). Tip from AUTODOC experts:
The replacement procedure is identical for the left and right brake calipers on the same axle.
Please note: all work on the car – VW FOX (5Z1, 5Z3) – should be done with the engine switched off.
Carry out replacement in the following order:
Step 1
Open the bonnet. Unscrew the brake fluid reservoir cap.
Step 2
Secure the wheels with chocks.
Step 3
Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 4
Raise the front of the car and secure on supports.
Step 5
Unscrew the wheel bolts.
AUTODOC recommends:
Important! Hold the wheel while unscrewing the fastening bolts. VW FOX (5Z1, 5Z3)
Step 6
Remove the wheel.
Step 7
Turn the steering knuckle to the right to get access to the brake hose bolt and brake pad wear sensor.
Please note!
If you use a jack, doing step #7 is impossible.
Step 8
Disconnect the ABS sensor electric socket. Disconnect the brake pad wear sensor plug. Remove the ABS sensor connector. Remove the connector of the brake pad wear sensor.
Please note!
Some cars are not equipped with the brake pad wear sensor.
Step 9
Put a container for gathering brake fluid beneath.
Step 10
Clean the area where the brake hose is connected to the caliper, and the guide pins area. Use a brake cleaner.
Replacement: brake caliper – VW FOX (5Z1, 5Z3). Tip:
After applying the spray, wait a few minutes.
Step 11
Clamp the brake hose off using a brake hose clamp.
Step 12
Unscrew the brake hose from the brake caliper. Use a combination spanner #11. Move the brake hose aside. Tie the brake hose to the car body with a hook or a piece of wire.
Step 13
Spread the brake pads. Use a crowbar.
Step 14
Remove the dust boot caps of the brake caliper guide pins. Use a flat screwdriver.
Step 15
Unscrew the brake caliper fastening. Use HEX No.H8. Use a ratchet wrench.
Step 16
Remove the brake caliper.
Replacement: brake caliper – VW FOX (5Z1, 5Z3). AUTODOC recommends:
When replacing a brake caliper it is recommended to replace brake pads, check the state of the brake discs and replace them with new ones if necessary.If going to use the old brake pads, clean them.
Step 17
Clean the brake caliper bracket from dirt and dust. Use a wire brush. Treat the brake caliper bracket. Use a brake cleaner.
AUTODOC recommends:
Replacement: brake caliper – VW FOX (5Z1, 5Z3). After applying the spray, wait a few minutes.
Step 18
Treat the contact surfaces between the brake pads and the brake caliper bracket. Use anti-squeal paste.
Step 19
Remove the guide pins from the brake caliper.
Step 20
Clean old grease and rust stains, if there are any, from the caliper guide pins and guide pin boots. Use a brake cleaner.
Replacement: brake caliper – VW FOX (5Z1, 5Z3). Tip:
After applying the spray, wait a few minutes.
Step 21
Lubricate guide pins with special brake grease.
AUTODOC recommends:
If no new guide pins were supplied in a kit with the new brake calipers, use the old pins.
Step 22
Install the brake caliper together with the pads.
Please note!
Install the brake caliper starting with its lower part.
Step 23
Screw in the guide pins.
Replacement: brake caliper – VW FOX (5Z1, 5Z3). Tip from AUTODOC:
Hold up the brake caliper.
Step 24
Tighten the guide pins. Use HEX No.H8. Use a torque wrench. Tighten it to 30 Nm torque.
Step 25
Clean dirt from the brake hose bolt. Use a brake cleaner.
AUTODOC recommends:
Replacement: brake caliper – VW FOX (5Z1, 5Z3). After applying the spray, wait a few minutes.
Step 26
Install and fix the brake hose into a new caliper. Use a torque wrench. Tighten it to 35 Nm torque.
Step 27
Install the dust boot caps of the brake caliper guide pins.
Step 28
Connect the ABS sensor electric socket. Connect the brake pad wear sensor plug.
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