Volkswagen New Beetle. Manual - part 84

 

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Volkswagen New Beetle. Manual - part 84

 

 

CALIPER HARDWARE 

Caliper Hardware 

below. 

NOTE: Determine cause and correct prior to repair or replacement of part. 

Base corroded, affecting performance 

Require repair or replacement. 

Base corroded, not affecting 
performance 

Suggest repair or replacement. 

Base loose, affecting performance 

Require repair or replacement. 

Base loose, not affecting performance 

Suggest repair or replacement. 

Burned out 

Require replacement. 

Intermittent 

Require replacement. 

Missing 

Require replacement. 

Seized in socket 

Require repair or replacement. 

Terminal broken 

Require repair or replacement. 

Terminal burned, affecting performance 

Require repair or replacement. See note 

below. 

NOTE: Determine cause and correct prior to repair or replacement of part. 

Terminal burned, not affecting 
performance 

Suggest repair or replacement. See note 

below. 

NOTE: Determine cause and correct prior to repair or replacement of part. 

Terminal corroded, affecting 
performance 

Require repair or replacement. 

Terminal corroded, not affecting 
performance 

Suggest repair or replacement. 

Terminal loose, affecting performance 

Require repair or replacement. 

Terminal loose, not affecting 
performance 

Suggest repair or replacement. 

Condition 

Code 

Procedure 

Bent 

Require repair or replacement. 

Broken 

Require repair or replacement. 

Corroded, affecting performance 

Require repair or replacement. 

Dust boots on slider pin (bolt) 
missing 

Require replacement of boots. 

Dust boots on slider pin (bolt) 
torn 

Require replacement of boots. 

Missing 

Require replacement. 

Shim bent 

Require removal or replacement. See note 

below. 

NOTE: Removal is acceptable if shim is not OE. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards BRAKE SYSTEMS

  

CALIPERS 

You are not required to replace or rebuild calipers in axle sets. However, when replacing or rebuilding a caliper 
due to the conditions that follow, you may suggest servicing, rebuilding, or replacement of the other caliper (on 
the same axle) for improved performance and preventive maintenance (for example, the part is close to the end 
of its useful life, replacing the caliper may extend pad life, or contribute to more balanced braking).  

Calipers 

Shim (OE standard) missing 

Require replacement. See note below. 

NOTE: Aftermarket shims may be suggested to reduce noise. 

Shim out of position 

Require removal or replacement. See note 

below. 

NOTE: Removal is acceptable if shim is not OE. 

Shim worn 

Require removal or replacement. See note 

below. 

NOTE: Removal is acceptable if shim is not OE. 

Slider pin (bolt) bent 

Require replacement of slider pin or bolt and 

lubricants. 

Slider pin (bolt) rust-pitted 

Require replacement of slider pin or bolt and 

lubricants. 

Slider pin (bolt) worn 

Require replacement of slider pin or bolt and 

lubricants. 

Threads damaged 

Require repair or replacement. 

Threads stripped (threads 
missing) 

Require replacement. 

Worn, affecting performance 

Require replacement. 

CAUTION: When installing loaded calipers, it is required that friction material be 

matched in axle sets for consistent braking characteristics. 

Condition 

Code 

Procedure 

Bleeder port damaged 

Require repair or replacement of caliper. 

Bleeder screw broken off in caliper 

Require repair or replacement of caliper. 

See note below. 

NOTE: Only required if the hydraulic system must be opened. 

Bleeder screw plugged 

Require repair or replacement of bleeder 

screw. See note below. 

NOTE: Only required if the hydraulic system must be opened. 

Bleeder screw seized 

Require replacement of caliper. See note 

below. 

NOTE: Seized is defined as a bleeder screw that cannot be removed after a practical 
attempt at removing. Only required if the hydraulic system must be opened. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards BRAKE SYSTEMS

  

CONTROLLERS 

See Electronic Controllers.  

DIGITAL RATIO AXLE CONTROLLERS AND BUFFERS (DRAC AND DRAB) 

Digital Ratio Axle Controllers and Buffers (DRAC and DRAB) 

Casting corroded, affecting structural 
integrity 

Require replacement. 

Casting damaged, affecting structural 
integrity 

Require replacement. 

Dust boot around caliper torn 

Require replacement of dust boot. 

Leaking 

Require repair or replacement. 

Mounting pin threads damaged 

Require repair or replacement of 

component with damaged threads. 

Mounting pin threads stripped in caliper 
bracket (threads missing) 

Require repair or replacement of caliper 

bracket. 

Mounting pin threads stripped in 
steering knuckle (threads missing) 

Require repair or replacement of steering 

knuckle. 

Mounting pin threads stripped (threads 
missing) 

Require repair or replacement of 

component with stripped threads. 

Parking brake cable support, lever, or 
return spring bent 

Require replacement of parts. 

Parking brake cable support, lever, or 
return spring broken 

Require replacement of parts. 

Parking brake mechanism in caliper 
inoperative 

Require repair or replacement. 

Piston corroded (pitted or peeling 
chrome plating) 

Require replacement of piston and 

rebuilding or replacement of caliper. 

Piston damaged, affecting performance 

Require replacement of piston and 

rebuilding or replacement of caliper. 

Piston damaged, not affecting 
performance 

No service suggested or required. 

Piston finish worn off 

Require replacement of piston and 

rebuilding or replacement of caliper. 

Piston sticking 

Require rebuilding or replacement of 

caliper. 

Slide mechanism sticking 

Require repair or replacement of slide 

mechanism. 

Condition 

Code 

Procedure 

Connector broken 

Require repair or replacement. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards BRAKE SYSTEMS

  

DISABLE SWITCHES 

See Switches.  

DRUMS 

Determine the need to recondition based upon individual drum conditions that follow. Friction material 
replacement does not require drum reconditioning unless other justifications exist. Do not recondition new 
drums unless they are being pressed or bolted onto an existing hub. It is not necessary to replace drums in axle 
sets. However, when replacing or reconditioning a drum due to the conditions that follow, you may suggest 
reconditioning of the other drum on the same axle to eliminate uneven braking behavior. Always wash drums 
after servicing or before installing.  

Drums 

Connector (Weatherpack type) leaking 

Require repair or replacement. 

Connector melted 

Require replacement. See note below. 

NOTE: Determine cause and correct prior to replacement of part. 

Connector missing 

Require replacement. 

Missing 

Require replacement. 

Output signal incorrect 

Require repair or replacement. 

Terminal burned, affecting performance 

Require repair or replacement. See note 

below. 

NOTE: Determine cause and correct prior to repair or replacement of part. 

Terminal burned, not affecting 
performance 

Suggest repair or replacement. 

Terminal corroded, affecting 
performance 

Require repair or replacement. 

Terminal corroded, not affecting 
performance 

Suggest repair or replacement. 

Terminal loose, affecting performance 

Require repair or replacement. 

Terminal loose, not affecting 
performance 

Suggest repair or replacement. 

Condition 

Code 

Procedure 

Balance weight missing 

No service suggested 

or required. 

Bell-mouthed, affecting performance 

Require 

reconditioning or 

replacement. 

Cooling fin broken 

No service suggested 

or required. 

Cracked 

Require replacement. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards BRAKE SYSTEMS

  

 

 

 

 

 

 

 

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