BRAKE FLUID DRAIN AND REFILL

 

Needed Parts

 

-DOT4 compliant brake fluid.  Do NOT use Silicon Based Brake Fluid (DOT 5).

 

Needed Tools

 

-Jack and Jackstands

-Wheel chocks (or a set of 2x4’s)

-Small blade screwdriver

-OEM VW lug remover

-17 mm socket

-10 mm socket

-10 mm open end wrench

-Brake fluid bleeder (or a rubber hose and a throw-away bottle)

-Torque wrench: range 11-125 Nm

 

 

i. Check your parts.  You should have: DOT4 compliant brake fluid.

 

ii. Drive your vehicle to the location where you will be performing the maintenance.  A flat spot of ground is preferable.  Put the transmission in gear and apply the parking brake.

 

iii. Initial conditions:  a.  The hood is open (refer to this procedure if needed)

b.      The rear end of the vehicle is raised (refer to this procedure if needed)

c.      The rear tires are removed (refer to this procedure if needed)

 

iv. Precautions:   a.  DOT4 brake fluid is corrosive!  Do not let any get on your

                        vehicle paint or it may eat through the clear coat.  Wash your

                             hands as soon as possible in the event of contact.

 

                        b.  In order to drain and refill the brake system, you will need to drain the fluid from each caliper line as well.  Start with the caliper furthest from the master cylinder and work your way forward.  The proper sequence is:  Right rear caliper, left rear caliper, right front caliper, and the left front caliper.  A general rule of thumb in order to flush a system is you want to purge at least 3 line lengths from the system or watch until the discharge fluid turns the same color as your new fill fluid.

 

Draining the old brake fluid, rear calipers

 

1.  Unscrew the cap from the top of the brake fluid reservoir and set it to the

     side.  Start the procedure from the passenger’s side caliper in the rear.

 

2.  a.  Remove the rubber cap from the bleeder valve.  You should be able to twist it

          off with your fingers.

 

     b.  Loosen the bleeder valve approximately ¼ turn with the 10 mm open end wrench, then quickly insert your tube.  ¼ turn should be sufficient to allow fluid to travel into your collection bottle.

 

3.  Fill the reservoir to the top with the new fluid.

 

4.  Proceed to slowly pump the brakes approximately 4-5 times.  The pedal should slowly go to the floor, while your fluid collection bottle should begin to fill with the old fluid.  Level in the brake fluid reservoir will begin to go down.  Do NOT let level go below the MIN mark, or overfill your collection bottle.

 

5.  a.  Repeat steps 3 and 4 until the fluid entering your collection bottle is the same

color and transparency as the new fluid. 

 

b.      When this is occurring, close the bleeder valve with your 10 mm open end wrench. 

 

c.      Remove the hose and torque the bleeder valve to 11 Nm.

 

d.      Reinstall the bleeder cap.

 

6.  Repeat steps 2 – 5 for the driver’s side caliper in the rear.

 

Draining the old brake fluid, front calipers

 

7.  a.  Go through the procedure to re-attach the rear wheels and lower the rear of

          the vehicle.

 

b.      Go through the procedure to jack up the front of the vehicle and remove the

          front tires.

 

c.      Start the next step with the caliper at the passenger’s side in the front.

 

8.  a.  Remove the rubber cap from the bleeder valve.  You should be able to twist it

          off with your fingers.

 

     b.  Loosen the bleeder valve approximately ¼ turn with the 10 mm open end wrench, then quickly insert your tube.  ¼ turn should be sufficient to allow fluid to travel into your collection bottle.

 

9.  Fill the reservoir to the top with the new fluid.

 

10.  Proceed to slowly pump the brakes approximately 4-5 times.  The pedal should slowly go to the floor, while your fluid collection bottle should begin to fill with the old fluid.  Level in the brake fluid reservoir will begin to go down.  Do NOT let level go below the MIN mark, or overfill your collection bottle.

 

11. a.  As before, repeat steps 9 and 10 until the fluid entering your collection bottle

          is the same color and transparency as the new fluid. 

 

b.      When this is occurring, close the bleeder valve with your 10 mm open end wrench.

 

c.      Remove the hose and torque the bleeder valve to 11 Nm.

 

d.      Reinstall the bleeder cap.

 

12.  Repeat steps 8 – 11 for the driver’s side caliper in the front.

 

13.  Go through the procedure to re-attach the front wheels and lower the front of the vehicle.

 

14.   a.  If the level of brake fluid is low, you may need to add additional fluid.  Once

             level is satisfactory, insert and tighten the cap.

 

       b.  Close the hood.