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How to change front brakes on a MK5 Golf

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...... http://www.brakepartssuperstore.org.uk/contents/en-uk/d12498.html

Brake Disc and Pad Replacement Procedure

  1. Open the bonnet and remove the brake fluid reservoir cap
  2. Loosen the wheel nuts and jack up the car, then remove the wheels
  3. Pop off the caliper carrier dust caps
  4. Loosen the caliper carrier bolts with the 7mm allen key (one at top and one at bottom)
  5. Remove the retaining clip on the brake caliper housing
  6. Remove the brake caliper using a pry bar or screwdriver, lever it away from the discs and pads
  7. Remove old pads (compare against new pads to make sure they're the right ones)
  8. Loosen the 21mm caliper mounting bolts with a socket and remove
  9. Using a T30 Torx remove the disc mounting screw and remove the disc (compare against the new disc to make sure it's right)
  10. 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
  11. 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
  12. 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
  13. Refit the brake caliper (removed in step 8) - remember to grease the bolts to aid removal in future
  14. 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
  15. Once you have put one brake pad on refit the caliper back to the hub - connect up the other brake pad
  16. Place the caliper back over the brakes and insert the carrier pins (make sure you grease these too)
  17. Refit the spring under tension
  18. Refit the wheel, spin it to check for any problems - lower car and tighten nuts
  19. Repeat for the passenger side, this has the ABS connector, take care not to damage on removal, procedure is the same as before
  20. When finished, top up any brake fluid as required, refit cap and pump the brakes
  21. 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.