Brake Pad Replacement

1. Raise and support vehicle. Remove front wheels.
2. Hold lower guide pin using an open end wrench. Remove lower caliper mounting bolt.
3. Push caliper assembly upward and swing out from bottom.
4. Siphon small amount of brake fluid from reservoir.
5. Remove pads and retaining springs from caliper support.
6. Replace pads exceeding wear limit. Wear limit of pads is .28" (7.0 mm), including backing plate.
7. Seat caliper piston fully into cylinder bore.
8. Install inner pad and then outer pad.
9. Swing caliper assembly down.
10. Hold lower guide pin using an open end wrench.
11. Install lower caliper mounting bolt.
12. Depress brake pedal several times to allow pads to move into operating position.
13. Ensure master cylinder reservoir fluid level is full.

Brake Shoe Replacement

1. Remove dust cap and cotter pin.
2. Loosen castellated nut.
3. Raise and support vehicle. Remove wheels.
4. Release parking brake at equalizer, and back off adjuster.
5. Remove drum retaining screws.
6. Remove drum. Ensure drum can rotate freely during removal.
7. After removing drum, remove retainer clips, hold-down springs and anchor pins.
8. Disconnect parking brake cable from lever on brake shoe.
9. Disconnect lower return and adjuster springs.
10. Pull brake shoes out of lower support.
11. Disconnect both upper return springs.
12. Remove both brake shoes from backing plate together with adjuster lever. Ensure both pistons remain in wheel cylinder.
13. Separate brake shoes from adjuster lever.
14. Remove parking brake lever from rear brake shoe.
15. To install brake shoes, reverse removal procedure steps 7 through 14.
16. Adjust brake shoes so distance from lining surface on leading shoe to lining surface on trailing shoe is 9.87" (250.7 mm).
17. Adjust parking brake at equalizer. There should be no free play between parking brake lever on brake shoe and adjusting rod.
18. Install brake drum by reversing removal procedure steps 1 through 6. Drum retaining screws must be tight.
19. Tighten castellated axle nut to 253 ft. lbs. (345 N.m).
20. Adjust parking brake, and depress brake pedal several times to set self-adjusting mechanism.

Parking Brake Adjustment

1. Raise and support vehicle. Release parking brake.
2. Tighten self-locking adjusting nut until there is no play at brake components.
3. Check for play by pulling on cable housings.
4. Apply and release parking brake several times.
5. Check adjustment by pulling parking brake handle up 2-4 notches. Rear wheels should be too tight to turn by hand.
6. Release parking brake. Rear wheels should rotate freely.

Master Cylinder Replacement

1. Remove instrument panel.
2. Drain master cylinder reservoir.
3. Disconnect brake lines and wiring at master cylinder.
4. Remove master cylinder from power assist servo.
5. To install, reverse removal procedure. Install new "O" ring between master cylinder and power assist servo.
6. Adjust brake push rod length.
7. Bleed hydraulic system.

Master Cylinder Push Rod Adjustment

Loosen lock nut on push rod. Turn clevis until distance between booster mounting flange and center of clevis eye is 4.40" (112 mm). Tighten lock nut.

Vacuum Power Assist Servo

1. Remove instrument panel.
2. Remove servo and master cylinder as an assembly.
3. Separate master cylinder from servo.
4. To install, reverse removal procedure.
5. Check and adjust push rod length.
6. Complete installation, and bleed hydraulic system.

   NOTE: Always replace damping ring, washer, filter and "O" ring (as equipped). Slots in damping washer and filter must be offset 180 degrees (if equipped).

Wheel Bearing Adjustment - Front

1. Tighten adjusting nut snugly while turning rotor.
2. Back off and retighten nut slowly until thrust washer can just be moved with screwdriver under finger pressure.
3. After adjustment, peen flange of NEW hub nut into spindle axle shaft recess.

   NOTE: FWD front wheel bearings and rear wheel bearings on Vanagon, also called hub or axle bearings, are sealed units with 1-piece outer race. Bearings are not adjustable.

Brake Pressure

Brake Pressure Adjustment

1. Raise and support vehicle. Attach Pressure Gauges (US 1016) to left front brake caliper and right rear brake cylinder. Bleed pressure gauge and hoses through valve on gauges.
2. Pump brake pedal several times. Remove nuts holding pressure regulator. Press on brake pedal until reading on both gauges is 725 psi (51 kg/cmý).
3. Tilt regulator forward 30 degrees. DO NOT damage brake lines when tilting regulator. Increase pressure on brake pedal until reading on gauge connected to front caliper reads 1450 psi (102 kg/cmý).
4. With regulator tilted forward 30 degrees and gauge for front caliper reading 1450 psi (102 kg/cmý), reading on gauge connected to rear brake cylinder must be 798-943 psi (56-66 kg/cmý). If reading is not within specified range, replace pressure regulator. Disconnect gauges and bleed brakes. When installing pressure regulator, ensure bolt heads face in forward (driving) direction.

Torque Specifications