Front caliper leaking fluid

[talljordan]

My front caliper was leaking fluid. When I took a look at it, there seem to be two pinhole leaks in the seal on the inside pison side. I suppose that is the dust cover??

Can just this piece be replaced? Or does the presence of fluid there mean that there is an inner seal as well that is blown?
_________________
1972 Super Beetle, Parked until adequate restoration funding is acquired in restoration!

Wanted: Male computer diagnostic plug end

[runamoc]

back when I was a paid mechanic, I told the boss I could rebuild brake 'stuff' cheaper. He told me it was a liability issue, replace with new parts. So...buy a new caliper.
_________________
Daily driver: '69 Baja owned 45 yrs - Plan B: '72 Ghia
Yard Art: 2 Sandrails
Outback: '69 Ghia - '68,'69,'70,'72 Beetle - '84 Scirocco, GTI - Pair of '02 Golfs- '80 Rabbit Diesel
VW Wiring = It's just wires

[ashman40]

Here’s a recent thread about a front caliper rebuild kit for an Empi disc brake setup. It details different part#s you could look for.
https://www.thesamba.com/vw/forum/viewtopic.php?t=807439

Most calipers have a square o-ring and a separate dust seal. The pressure is held by the o-ring. So if there is fluid dripping out around the dust seal it likely means the o-ring has failed. The question is WHY did it fail? If the o-ring failed because the piston sides are not completely smooth, it means the piston will chew up any new o-ring you install. You will need a new piston. At which point it is probably cheaper to just replace the entire caliper.
I personally have no issue with rebuilding calipers. This is often needed on older cars/motorcycles where you can no longer find new parts. But the Beetle front calipers are often the same calipers used on Ghias and readily available from the aftermarket. Price a new caliper and judge for yourself if it is worth your time and $$ to rebuild vs. replace it. Last time I looked, the price of a new Ghia caliper was anywhere from $50-$200! The rebuild kit may be 40% the cost of the a new caliper!
_________________
AshMan40
---------------------------
'67 Beetle #1 {project car that never made it to the road }
'75 Beetle 1200LS (RHD Japan model) {junked due to frame rot}
'67 Beetle #2 {2019 project car - Wish me luck!}

[viiking]

I've rebuilt OEM VW calipers in the past and it is quite easy, but as Ashman has said you need to know why it leaked The leak is in the piston seal not the dust seal.

The only thing to think of however is that if you are going to replace a caliper you should do both sides unless you can positively determine the make of the original caliper.
_________________
1968 1500 RHD Lotus White Beetle since birth. In the hospital for major surgery
1966 Lancia Flavia Pininfarina Coupe - in the waiting room
Discharged: 1983 Vanagon, 1974 1800 Microbus,1968 Low Light,1968 Type 3

[talljordan]

Both sides are brand new Varga calipers from topline with less than 4000miles on them
_________________
1972 Super Beetle, Parked until adequate restoration funding is acquired in restoration!

Wanted: Male computer diagnostic plug end

[Tim Donahoe]

Jordan, replace the caliper entirely. I had great luck with an EMPI front disc conversion on my 1974 Super Beetle, but this was in 2012 (cost was $220 back then for the whole kit, minus new bearings), but I can't vouch for the quality today.

If it were me, I'd buy the new calipers from Topline. Even the Chinese calipers are good, and less expensive. I haven't been to the site in a few years, but everything front-end related I once bought from them was top notch.

Tim
_________________
Let's do the Time Warp again!

Richard O'Brien

[viiking]

[edjose17]

On Amazon right now.

3116151078EC Front Brake Caliper for VW Karmann Ghia

https://www.amazon.com/dp/B00QXX17A0?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_3

[talljordan]

I called topline today and they said they would work something out with me tomorrow. I suspect they are out of waranty because I bought them more than a year ago.

I'm not going to replace a nice varga caliper with a shitty chinese one. So if a new caliper goes on, it'll be a new one from Varga.
_________________
1972 Super Beetle, Parked until adequate restoration funding is acquired in restoration!

Wanted: Male computer diagnostic plug end

[Cusser]

[talljordan]

Jon at topline sent me a new caliper no issue. They have amazing customer service.

Arrived today and the quality of these varga calipers seems honestly not great. It noticeably does not line up. Im going to run it for now, but I have concerns for sure. Will email Jon and report back. It may just be cosmetic.

Maybe the chinese calipers are better after all, they certainly are cheaper. FWIW these vargas are sourced via EMPI. Big EMPI sticker on the box.

_________________
1972 Super Beetle, Parked until adequate restoration funding is acquired in restoration!

Wanted: Male computer diagnostic plug end

[viiking]

If you’re worried about the fact that the caliper halves do not line up exactly I wouldn’t.

Here’s a photo of the original VW ATE that I gave in my 68 Euro Beetle. You can see that it doesn’t line up perfectly side to side. When the new manufacturer copied the original design they probably copied the “error” exactly.

_________________
1968 1500 RHD Lotus White Beetle since birth. In the hospital for major surgery
1966 Lancia Flavia Pininfarina Coupe - in the waiting room
Discharged: 1983 Vanagon, 1974 1800 Microbus,1968 Low Light,1968 Type 3

[talljordan]

Root cause of the issues in the original caliper is found. The caliper seal was twisted. Likely was twisted during installation of the piston at the factory.

I simply popped out the pistons to find this.

_________________
1972 Super Beetle, Parked until adequate restoration funding is acquired in restoration!

Wanted: Male computer diagnostic plug end

[MTT3107]

Good for you, that they responded like that !

I just ran into another issue with the front brake calipers on the Ghia I am currently working on.

Car had been sitting for a long time before I bought it and started working on it.
Among other things, I decided to replace, the brake pads.
No big deal, right ?

Until I found that each caliper had one piston frozen solid, could not get it pushed back to get the new pads in, no matter what.
Started searching around for repair kits, etc., when I found a set of brand new calipers, including pads, for $99 on Amazon….
Seemed to me a much better option than messing around with the old calipers.

[talljordan]

Personally I would have preferred some OEM calipers. They can be rebuilt!
_________________
1972 Super Beetle, Parked until adequate restoration funding is acquired in restoration!

Wanted: Male computer diagnostic plug end

[Tim Donahoe]

All I can add is to repeat that the EMPI disc conversion kit that I got in 2012, worked fine, with no leaks, or any other issues, except, when braking, an annoying squealing sound from the pads during the first 200 miles (soft pads). The calipers in the kit worked well, and the rotors were very well made, fitting my old races and bearings perfectly.

Tim
_________________
Let's do the Time Warp again!

Richard O'Brien

[Bobs67vwagen]

I would get a rebuild kit for the failed caliper, assemble it, put it in a plastic bag, and save it as a spare.