Rear disc upgrade = NO parking brake!

[dobryan]

[dgbeatty]

A couple (or more) things are important.
Replace the cables. with a pair of overly long versions (oe part number 441 609 721 D or GEMO 402248). Remove the inner wires and heavily lube them with a compatible grease. Cut the housing to the new required lengths. Reassemble. Cut the inner wire to the new correct length. Throughly degrease the last inch or so and sweg on new stops then solder them in place using acid core solder. Completely clean the flux away when finished.
You are halfway there.
Remove the front cable, clean and relube. Lube the pivot points on the handle assemble. Next is another change. Install the heavy version of the return springs on the calipers. Refer to photographs. The new cables should be supported. An extra heavy duty tie strap works well if not elegantly.
I saved the most important step for last. It is the proper operation which is widely overlooked. When setting the handbrake on this type of caliper the foot brake "MUST BE FIRMLY DEPRESSED WHILE THE HANDBRAKE IS BEING SET"! This applies regardless of make ie Porsche, VW, Ford whatever. This is the most important step period! But like a lot of things these days the automakers have given up on driver training and have automated the parking brake with electric servos that fully apply and release the calipers automatically as called for by an algorithm.

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Schau in das Buch

[Crankey]

I bought burlys kit about 6 years ago.
I'm concidering just dumping it completely for a new GoWesty kit that promises 30% more hand brake force.
Any duplicate parts can go on the spare part shelf I spose but I like the catharsis of tossing into the scrap metal bin too.

[mtnhome]

[dobryan]

[Sodo]

[dobryan]

I have Burley’s newest rear disc brake kit for the Western Syncro. It is supposed to have a good parking brake. I’ll report back this spring after the full mechanical rehab.
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Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371

The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794

[mtnhome]

[Crankey]

[leecat]

Admittedly I haven't read this entire thread, but I've found it far easier to install Audi electric rear brakes if you have a rear disc setup. The Audi electric calipers bolt straight up to one mounting hole (if you're running A3 - and I suspect A4 discs) and only need a small bracket fabbed up to attach to the other mounting hole. Brake line fittings are identical VW-to-Audi.

Then instead of fighting with cables and adjusters and springs, it just requires a wire to a momentary switch on the dash - hold that switch down and the e-brake locks right up. Brush the switch gently and you can set the pressure on the rear brakes by feel.

If you're running 14 inch rims, the Audi calipers need to have about 1/8" ground off the 'hump' at the back of them to clear the rim. Very simple to install and can be done in less than a day - IF you already have rear discs, of course.

[Sodo]

[skills@eurocarsplus]

[Sodo]

[Crankey]

In the rainy winter, on a hill waiting on a light I've definitely needed the hand brake to guarantee no back roll as I engage the clutch because the guy behind me was too close for comfort.
Can electric park brake do that ? Or are they just on/off with a button ? I've never had those before..

[skills@eurocarsplus]

[Zeitgeist 13]

Suspension and underbody stuff just doesn't rust out here in the PNW, like it does in the rustbelt or Europe. That's a moot point.

Just use '01-'03 T4 rear brakes, and be done with it. They're proven to work great on similarly sized and weight rigs
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[dobryan]

[Zeitgeist 13]

Believe me, my specialties are Transporters and MB 124s; both of which are known to rust from the bottom up in other markets. They just simply don't here in the PNW. Both will rust around the window perimeters and along the body seams, but that's it. I currently have a '73 Super Beetle here with intact original pans and front frame horn. The only rust is in the rear half moon ventilation ducts. That's virtually unheard of in most other Northern hemisphere markets.
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[Sodo]

The Jetta cables that I got at the junkyard were 2006 and are in perfect condition.
Very nice OEM quality.
I will try to grease them.
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[Franklinstower]