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How to change the Front Discs(rotors) and Pads on a 2011 T3 Rate Topic: -----

#1 User is offline   Loz 

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Posted 16 June 2014 - 04:32 PM

Mileage has reached 44400 and Pedal travel has increased and braking hasn't been quite so good lately so I thought I would push on and replace the pads and as this is my second set of pads I will also change the disks.

I purchased the disks and pads from Amazon as they were stocking original Brembo parts for the car. The fitting kit was ordered from the dealer and the dial wear sensor from Fleabay.

Here are the part numbers are used for the job:
Item ------------(PR-No) - VW Part Number -- Brembo part number
Front Brake Pads 1LC -- 7L6 698 151J -- P85110
Front Wear sensor 1LC -- 7P0 907 637 (this is the original single one not used by me) this is the Fleabay part I actually used http://www.ebay.co.uk/itm/191120924139
Front Disc L 1LA,1LC,1LE -- 7L6 615 301 (N) -- 09.9867.11
Front Disc R 1LA,1LC,1LE -- 7L6 615 302 (N) -- 09.6868.11
Front Pad Fixing Kit 1LC 7L6 698 269

First inspection showed the lip if the disk just starting to cut into the wear indicator and a measure of the disk showed it as having dropped below the minimum thickness for the discs.
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You can also see that I currently only have the single wear sensor which I will be replacing with the older double wear sensor cable from the T2 that I sourced from Fleabay.

Next I disconnected the wear sensor from its carrier and cleaned up the connector with my brake cleaner spray.
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I then used my vacuum and bleeding kit to remove some fluid from the reservoir.
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Next job is to use a pin punch to knock the retaining pins out of the caliper.
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As I am replacing these they can be discarded together with the metal retaining clip.

Using a large screwdriver I gently levered back the pads against the pistons enough to slide them out of the caliper.
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Next, insert the piston retractor which winds outwards and pushes the pistons back into the caliper, pause halfway and double check the reservoir and make sure you're not overfilling it. (Chaser rightly recommends opening the bleed nipple so as not to push back into the system, but I didn't want to bleed the brakes afterwards)
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If you're only changing pads then your next job is to just clean out the slots where the pads have come out from to remove the buildup of brake dust that may stop the pads from moving freely and fit your new pads.
As I am changing the discs we will move on to removing the caliper.

COUNTD.
Regards Loz

VW California T6 MY17 204 DSG 4motion in Blackberry
Vag-Com if anyone in area needs to use it...
(previous)2011 T3 Escape - 2010 Tiguan R-Line 170 - 2010 Golf 170GTD DSG - Landcruiser 78 series(Troopie)
(previous)2009 Golf 140GT DSG - 2007 Shogun Warrior 3.2 SWB - 2001 Discovery 2
(previous)1999 Audi 2.4SE Avant....>>>>>>> way back.. Ford Mk1 Capri

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#2 User is offline   Loz 

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Posted 16 June 2014 - 04:58 PM

Next remove the hex bolt that holds the brake pipe into the back of the upright, this will allow us to move the caliper away from the hub without disconnecting the brake hose.
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Next support the caliper with a strap and remove the 2 bolts holding the caliper to the hub. Move the calliper out of the way making sure you don't put any strain on the brake pipes.
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Next remove the TORX bolt holding the disk to the hub.
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The disc will now come away from the hub with a little persuasion from a rubber or hyde mallet. Warning, they are heavier than they look so don't let them fall on you.

At this point I temporarily bolted the caliper back to the hub to allow me to clean out the brake caliper thoroughly as there was quite a bit of buildup. I used methylated spirits and the aerosol brake cleaner and a wire brush. The caliper on the near side actually had the brake pad corroded in place and required the use of a Dremel to clean up the surface.
Having cleaned up the caliper and also wire brushed the hub and make sure there was nothing on the surface of the hub I fitted the new disc, bolting the TORX screw to hold it in place.
I then put the caliper back on and torqued it up to 270NM (in english that is F-Tight and a bit more) and remounted the bracket holding the brake pipe.

Next the pads, fitting kit and dual wear sensor.
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Finally mounted a dial gauge to check for runout. Job Done.
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Regards Loz

VW California T6 MY17 204 DSG 4motion in Blackberry
Vag-Com if anyone in area needs to use it...
(previous)2011 T3 Escape - 2010 Tiguan R-Line 170 - 2010 Golf 170GTD DSG - Landcruiser 78 series(Troopie)
(previous)2009 Golf 140GT DSG - 2007 Shogun Warrior 3.2 SWB - 2001 Discovery 2
(previous)1999 Audi 2.4SE Avant....>>>>>>> way back.. Ford Mk1 Capri

Tip! Search this forum using google with [site:www.mytreg.com word word word ]

#3 User is offline   dailysmoker 

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Posted 16 June 2014 - 05:09 PM

Great post(s) Loz

I might be doing the pads on my Treg soon and it will be all the easier now!

DS


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#4 User is offline   Leeeeee 

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Posted 16 June 2014 - 06:49 PM

Nice write up.
2007 Treg V6 TDI

#5 User is offline   Cass 

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Posted 16 June 2014 - 11:18 PM

Great thread Loz and pics beneficial as ever.

What mileage have you done and any warning fault with the dual wear sensor wiring :huh:
Current - 2013 R-Line 245 PS in Pure White Special, 12 way Elec Seats in Vienna, Memory Pack, Air Susp CDC, Retractable Towbar, TPMS and Spacesaver Spare - Gtechniq TSP treatment : )

Previous - 2012 VW Touareg Altitude 3.0 TDI 245PS, Deep Black Pearlescent and 2009 VW Touareg Altitude 3.0TDI 240PS, Diamond Black Pearlescent

#6 User is offline   Loz 

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Posted 17 June 2014 - 06:05 AM

Cass said:

1402960704[/url]' post='275729']
Great thread Loz and pics beneficial as ever.

What mileage have you done and any warning fault with the dual wear sensor wiring :huh:


44k and no issues with the sensor. I'll add the mileage to the top. Thanks.
Regards Loz

VW California T6 MY17 204 DSG 4motion in Blackberry
Vag-Com if anyone in area needs to use it...
(previous)2011 T3 Escape - 2010 Tiguan R-Line 170 - 2010 Golf 170GTD DSG - Landcruiser 78 series(Troopie)
(previous)2009 Golf 140GT DSG - 2007 Shogun Warrior 3.2 SWB - 2001 Discovery 2
(previous)1999 Audi 2.4SE Avant....>>>>>>> way back.. Ford Mk1 Capri

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#7 User is offline   roytour 

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Posted 17 June 2014 - 06:36 AM

Loz, Great write up, did you smear a thin layer of copper grease on the hub to stop future seizing of the disc?
2014 R-Line 245 PS in Pure White Special, 12 way Elec Seats in titan black, Memory Pack, Air Susp CDC, Retractable Towbar, TPMS and Spacesaver Spare, Area View, Rear sunblinds, Parking Heater, heated front windscreen, Google Earth - oh yes and a heated steering wheel :)

Gone but not forgotten - 58 plate altitude v6 3.0 240ps

#8 User is offline   Loz 

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Posted 17 June 2014 - 07:56 AM

 roytour, on 17 June 2014 - 06:36 AM, said:

Loz, Great write up, did you smear a thin layer of copper grease on the hub to stop future seizing of the disc?


Not required as the contact area in the centre is tiny and the face needs to be clean to avoid runout.
Regards Loz

VW California T6 MY17 204 DSG 4motion in Blackberry
Vag-Com if anyone in area needs to use it...
(previous)2011 T3 Escape - 2010 Tiguan R-Line 170 - 2010 Golf 170GTD DSG - Landcruiser 78 series(Troopie)
(previous)2009 Golf 140GT DSG - 2007 Shogun Warrior 3.2 SWB - 2001 Discovery 2
(previous)1999 Audi 2.4SE Avant....>>>>>>> way back.. Ford Mk1 Capri

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#9 User is offline   roytour 

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Posted 17 June 2014 - 09:25 AM

 Loz, on 17 June 2014 - 07:56 AM, said:

Not required as the contact area in the centre is tiny and the face needs to be clean to avoid runout.


Runout ?
2014 R-Line 245 PS in Pure White Special, 12 way Elec Seats in titan black, Memory Pack, Air Susp CDC, Retractable Towbar, TPMS and Spacesaver Spare, Area View, Rear sunblinds, Parking Heater, heated front windscreen, Google Earth - oh yes and a heated steering wheel :)

Gone but not forgotten - 58 plate altitude v6 3.0 240ps

#10 User is offline   Loz 

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Posted 17 June 2014 - 10:38 AM

 roytour, on 17 June 2014 - 09:25 AM, said:

Runout ?


where the disc is either not mounted flat on the hub or possibly even warped the disk would wobble.
As directed by the manual I fitted a magnetic dial gauge to measure the runout(wobble?) on the edge of the disk and it must be within 0.001 of a mm
Regards Loz

VW California T6 MY17 204 DSG 4motion in Blackberry
Vag-Com if anyone in area needs to use it...
(previous)2011 T3 Escape - 2010 Tiguan R-Line 170 - 2010 Golf 170GTD DSG - Landcruiser 78 series(Troopie)
(previous)2009 Golf 140GT DSG - 2007 Shogun Warrior 3.2 SWB - 2001 Discovery 2
(previous)1999 Audi 2.4SE Avant....>>>>>>> way back.. Ford Mk1 Capri

Tip! Search this forum using google with [site:www.mytreg.com word word word ]

#11 User is offline   roytour 

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Posted 17 June 2014 - 12:13 PM

 Loz, on 17 June 2014 - 10:38 AM, said:

where the disc is either not mounted flat on the hub or possibly even warped the disk would wobble.
As directed by the manual I fitted a magnetic dial gauge to measure the runout(wobble?) on the edge of the disk and it must be within 0.1 of a mm


technical :)
2014 R-Line 245 PS in Pure White Special, 12 way Elec Seats in titan black, Memory Pack, Air Susp CDC, Retractable Towbar, TPMS and Spacesaver Spare, Area View, Rear sunblinds, Parking Heater, heated front windscreen, Google Earth - oh yes and a heated steering wheel :)

Gone but not forgotten - 58 plate altitude v6 3.0 240ps

#12 User is offline   Caladan 

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Posted 17 June 2014 - 04:31 PM

How easy are the rear caliper bolts to get at on a T3 Loz? Remember half killing myself to get the V10 rear torx's undone...

And who do you use for the parts? I got stung by a firm that sent me the wrong pads and then when I returned then disavowed any knowledge of receiving them..of course I had not used registered mail :(

Caladan
Current: 3.0L R-line White, Moonrock Vienna seats, piano black inserts, CDC, air-bag pack, parking heater/heated screen, towbar, Dynaudio, sun-blinds, blind spot assist, traffic sign recog., aerial view, dynamic light assist, Pikes Peak Summers, Karakum Winters.
Previous: Touareg V10

#13 User is offline   Loz 

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Posted 17 June 2014 - 06:40 PM

 Caladan, on 17 June 2014 - 04:31 PM, said:

How easy are the rear caliper bolts to get at on a T3 Loz? Remember half killing myself to get the V10 rear torx's undone...

And who do you use for the parts? I got stung by a firm that sent me the wrong pads and then when I returned then disavowed any knowledge of receiving them..of course I had not used registered mail :(

Caladan


I used the Brembo aftermarket app(on web also) to find the Brembo part number then searched 'Tinternet and found that Amazon of all places had stock of discs and pads, delivered in 2 days!



Regards Loz

VW California T6 MY17 204 DSG 4motion in Blackberry
Vag-Com if anyone in area needs to use it...
(previous)2011 T3 Escape - 2010 Tiguan R-Line 170 - 2010 Golf 170GTD DSG - Landcruiser 78 series(Troopie)
(previous)2009 Golf 140GT DSG - 2007 Shogun Warrior 3.2 SWB - 2001 Discovery 2
(previous)1999 Audi 2.4SE Avant....>>>>>>> way back.. Ford Mk1 Capri

Tip! Search this forum using google with [site:www.mytreg.com word word word ]

#14 User is offline   Caladan 

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Posted 18 June 2014 - 12:21 AM

 Loz, on 17 June 2014 - 06:40 PM, said:

I used the Brembo aftermarket app(on web also) to find the Brembo part number then searched 'Tinternet and found that Amazon of all places had stock of discs and pads, delivered in 2 days!

Assume you download the instructions to your Kindle..thx :rolleyes:
Current: 3.0L R-line White, Moonrock Vienna seats, piano black inserts, CDC, air-bag pack, parking heater/heated screen, towbar, Dynaudio, sun-blinds, blind spot assist, traffic sign recog., aerial view, dynamic light assist, Pikes Peak Summers, Karakum Winters.
Previous: Touareg V10

#15 User is offline   Loz 

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Posted 18 June 2014 - 06:21 AM

Brembo app on the iPad and manual on the Kindle App :)
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Regards Loz

VW California T6 MY17 204 DSG 4motion in Blackberry
Vag-Com if anyone in area needs to use it...
(previous)2011 T3 Escape - 2010 Tiguan R-Line 170 - 2010 Golf 170GTD DSG - Landcruiser 78 series(Troopie)
(previous)2009 Golf 140GT DSG - 2007 Shogun Warrior 3.2 SWB - 2001 Discovery 2
(previous)1999 Audi 2.4SE Avant....>>>>>>> way back.. Ford Mk1 Capri

Tip! Search this forum using google with [site:www.mytreg.com word word word ]

#16 User is offline   Mark Miwurds 

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Posted 20 November 2015 - 08:22 AM

 Loz, on 18 June 2014 - 06:21 AM, said:

Brembo app on the iPad and manual on the Kindle App :)
image.jpg image.jpg image.jpg


Loz - great write up & very useful. My 30,000 mile 2013 R-Line isn't braking as well as it did and as I said in a previous post VW want £1,000 to replace disks & pads all round. A couple of questions if I may (it's actually three ...)

1. How on earth do you find out what parts are required as everywhere I look, even if I type in my vehicle details precisely, there seem to be several options for both disks and pads?
2. You make reference to measuring minimum thickness of discs and thus working out they need replacing - how do you know what the minimum thickness is?
3. I intend to extend my T3's warranty to 5 years (having had the very expensive engine out oil leak fixed under warranty). What am I allowed to do in terms of replacing parts like brakes without voiding the warranty - i.e. do I have to buy obviously VW stamped parts?

Thanks, MMW
Night blue Touareg 245PS R-Line (cameras, & active cruise - which is the coolest thing ever!)
Bright red Porsche Boxster (with sports exhaust = great noise!)

#17 User is offline   Loz 

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Posted 20 November 2015 - 09:13 AM

 Mark Miwurds, on 20 November 2015 - 08:22 AM, said:

Loz - great write up & very useful. My 30,000 mile 2013 R-Line isn't braking as well as it did and as I said in a previous post VW want £1,000 to replace disks & pads all round. A couple of questions if I may (it's actually three ...)
Thanks, MMW


1. How on earth do you find out what parts are required as everywhere I look, even if I type in my vehicle details precisely, there seem to be several options for both disks and pads?
I use the brembo online catalogue or if you have an iPad they have an app. There are a few OEM manufacturers like Texar and Pagid and Brembo.

Pick up the part number and you might find them on Amazon like I did;

Rear Pads Brembo P65027 Rear Disc Brake Pad, Set of 4


Rear Discs Brembo 09.A056.11 Rear Brake Disc, Set of 2


Left Front Disc
Brembo 09.9867.11 Front UV Coated Brake Disc - Single Piece

Right Front Disc
Brembo 09.9868.11 Front UV Coated Brake Disc - Single Piece

Front Pads
Brembo P85110 Front Disc Brake Pad - Set of 4

You may also need replacement wear sensors, I prefered to locate the T2 wear sensors that clip into both pads.

There is also a pin and spring-plate kit for the fronts but mine were reusable.

2. You make reference to measuring minimum thickness of discs and thus working out they need replacing - how do you know what the minimum thickness is?
If you select the Disc in the catalogue it has all the techinfo, minimum thickness is 30mm but you will need an outside caliper to measure or if you feel a lip that is deeper than 1mm then that's it.

3. I intend to extend my T3's warranty to 5 years (having had the very expensive engine out oil leak fixed under warranty). What am I allowed to do in terms of replacing parts like brakes without voiding the warranty - i.e. do I have to buy obviously VW stamped parts?

No issues,

Just to add, The Brembo Discs are all enamelled so no unsightly rusting unlike all the others (including VW supplied)

When doing the Discs you have to unbolt the calipers and the fronts need a humongous amount of torque and I had to buy a big torque wrench for the job.
Regards Loz

VW California T6 MY17 204 DSG 4motion in Blackberry
Vag-Com if anyone in area needs to use it...
(previous)2011 T3 Escape - 2010 Tiguan R-Line 170 - 2010 Golf 170GTD DSG - Landcruiser 78 series(Troopie)
(previous)2009 Golf 140GT DSG - 2007 Shogun Warrior 3.2 SWB - 2001 Discovery 2
(previous)1999 Audi 2.4SE Avant....>>>>>>> way back.. Ford Mk1 Capri

Tip! Search this forum using google with [site:www.mytreg.com word word word ]

#18 User is offline   Mark Miwurds 

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Posted 20 November 2015 - 11:07 AM

 Loz, on 20 November 2015 - 09:13 AM, said:

1. How on earth do you find out what parts are required as everywhere I look, even if I type in my vehicle details precisely, there seem to be several options for both disks and pads?
I use the brembo online catalogue or if you have an iPad they have an app. There are a few OEM manufacturers like Texar and Pagid and Brembo.

Pick up the part number and you might find them on Amazon like I did;

Rear Pads Brembo P65027 Rear Disc Brake Pad, Set of 4


Rear Discs Brembo 09.A056.11 Rear Brake Disc, Set of 2


Left Front Disc
Brembo 09.9867.11 Front UV Coated Brake Disc - Single Piece

Right Front Disc
Brembo 09.9868.11 Front UV Coated Brake Disc - Single Piece

Front Pads
Brembo P85110 Front Disc Brake Pad - Set of 4

You may also need replacement wear sensors, I prefered to locate the T2 wear sensors that clip into both pads.

There is also a pin and spring-plate kit for the fronts but mine were reusable.

2. You make reference to measuring minimum thickness of discs and thus working out they need replacing - how do you know what the minimum thickness is?
If you select the Disc in the catalogue it has all the techinfo, minimum thickness is 30mm but you will need an outside caliper to measure or if you feel a lip that is deeper than 1mm then that's it.

3. I intend to extend my T3's warranty to 5 years (having had the very expensive engine out oil leak fixed under warranty). What am I allowed to do in terms of replacing parts like brakes without voiding the warranty - i.e. do I have to buy obviously VW stamped parts?

No issues,

Just to add, The Brembo Discs are all enamelled so no unsightly rusting unlike all the others (including VW supplied)

When doing the Discs you have to unbolt the calipers and the fronts need a humongous amount of torque and I had to buy a big torque wrench for the job.


Thank you for that, clearer now. I'd already spotted the 270NM - mine's only rated to 200NM, so as you say humungous ...
Night blue Touareg 245PS R-Line (cameras, & active cruise - which is the coolest thing ever!)
Bright red Porsche Boxster (with sports exhaust = great noise!)

#19 User is offline   FISHBOY 

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Posted 20 November 2015 - 11:20 AM

:twoup: Top guide.

Boy you got some nice tools...
Landrover Discovery 4.5 - Last of the HSE
Renault Clio 197 RS Cup - 1,200kg Recaro and Brembo kitted 197bhp go kart.

Used to have
T4 262 Moonlight Blue R line on 21"s
Landrover Discovery 3 HSE
Subaru Impreza WRX
Seat Leon Cupra 20VT
Vauxhall Astra GSI
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#20 User is offline   johnb80 

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Posted 20 November 2015 - 11:36 AM

Great write up, just a couple of minor points.....

1) why rubber or Hyde mallet when taking off the old disks, they're scrap anyway.
2) I would check the runout before refitting the calliper just in case it all has to come off again.

J
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