this has come up many times...parts list is as follows

G60 Caliper Carriers

G60 Calipers

G60 Brake Hoses

16v Hubs

G60 Discs

G60/16v Pads (same IIRC)

OR

G60 Caliper Carriers

16v Calipers with the slider pin heads shaved 2mm

16v Brake Hoses

16v Hubs

G60 Discs

G60/16v pads

obviously if you already have a 16v then u can scratch those parts from the list... i personally done it the second way as then the only part thats hard to get is the carriers...

theres no need for a how-2-guide as when u strip the brakes u currently have the new bits will go on in reverse..

please note that i done it the second way which is a piece of cake, you may need to change bits like wheel bearings on second hand 16v hubs and perhaps you will need to change your balljoints when moving from 8v to 16v hubs

i take it you mean shave 2mm from the end of the sliders length and not the diameter tej??

from the actual head of the slider pins... the part with the hex on it for holding them

heres a guide

whats the difference between 16V hubs and my 1.6cl hubs ??

heres a guide

thats the stuff

although that person has neglected the thickness difference between G60 and 16v discs... but as he has used old pads it will go together fine... but as soon as he tries to get some new pads on there he'll be stuck!

to use the 16v calipers you must shave down the slider pins 2mm if you ever want to fit new pads

whats the difference between 16V hubs and my 1.6cl hubs ??

the 16v hubs have seperate caliper carriers, whereas the 8v hubs have them built in to the hub

to use the 16v calipers you must shave down the slider pins 2mm if you ever want to fit new pads

I think I'm going to have a go at this when I renew my discs.

Sorry for being thick, but where are the slider pins? And how easy is it to shave 2mm off them?

slider pins are what hold the caliper to the carrier...or more accuratley let the caliper slide forwards and backwards

the heads are hex (15mm or something) and u hold this with an open ended spanner when undoing the bolts that hold the caliper to them... shaving down 2mm off the heads is best done in a lathe and wont take more than a few mins

however u will need a fairly slim spanner from then on to hold the head when u fit the caliper bolts

i have just picked up the complete setup

G60 Caliper Carriers

G60 Calipers

G60 Brake Hoses

16v Hubs

G60 Discs

G60/16v Pads (same IIRC)

so in effect i simply unbolt all the standard lot and refit the new lot? i know it wont be quite that simple

i have never tackled changing anything of this nature before so do the brakes need to be bled and and then fitted with new fluid??

yep it all swaps straight over...

and you will need to bleed the brakes afterwards...always a must as soon as you disturb a brake hose

will i have to have a certain offset to clear the new calipers?

the wheels i am running are et43 so are pretty well tucked in, just want to be sure that run into no probs next week when i fit them!

cheers!

slider pins are what hold the caliper to the carrier...or more accuratley let the caliper slide forwards and backwards

the heads are hex (15mm or something) and u hold this with an open ended spanner when undoing the bolts that hold the caliper to them... shaving down 2mm off the heads is best done in a lathe and wont take more than a few mins

however u will need a fairly slim spanner from then on to hold the head when u fit the caliper bolts

what does this shaving the head of the bolt achieve?

why does it need to be done?

I'm just away to do this conversion, parts are in the post

slider pins are what hold the caliper to the carrier...or more accuratley let the caliper slide forwards and backwards

the heads are hex (15mm or something) and u hold this with an open ended spanner when undoing the bolts that hold the caliper to them... shaving down 2mm off the heads is best done in a lathe and wont take more than a few mins

however u will need a fairly slim spanner from then on to hold the head when u fit the caliper bolts

what does this shaving the head of the bolt achieve?

why does it need to be done?

I'm just away to do this conversion, parts are in the post

This is because the lucas calipers fitted to the G60 are actually wider than the ones on the polo 16v in order to accommodate the 280mm discs which are slightly thicker than the 256mm ones. Therefore, shaving this 2mm off the slider pins allows the narrower 16v calipers to open wider, and give the extra clearance needed to accommodate the pads and the thicker disc.

I've gone the alternative route and actually sourced some G60 calipers to go with the carriers, and therefore I won't need to shave off that 2mm. But I'm setting myself up for the added ballache that as I'm fitting new calipers, I'm going to have to bleed the brakes afterwards, which I'm not looking forward to.

am just wondering will i be able to change everything from a ibiza cupra sport 2.0 16v cos there 280mm brake set up?

i got g60 calipers carriers disks and pads to go on my diesel polo mk4 doing them now ready for a pd150 conversion later in the year problem is my hubs are slightly smaller and a few of my fellow dubbers have told me i need to uprate my master cylinder too can i get spigot rings to centralise the disks (like the vauxhall 288 upgrade on a corsa sorry to bring a non vag up lol) or will i have to source hubs if so which ones and do i need to uprate the master cylinder and off what car?

cheers

chris

Ok I've just bought a g60 caliper and carrier setup and getting all the other bits such as hoses pads and discs.

On my 1.6CL will i for sure have to change ball joints and if so is this costly and straight forward?

Ok I've just bought a g60 caliper and carrier setup and getting all the other bits such as hoses pads and discs.

On my 1.6CL will i for sure have to change ball joints and if so is this costly and straight forward?

If its not a 16v, youl need hubs which arent usualy cheap! balljoints, track rods, brake hoses should all fit though

I can obtain the hubs and wheel bearings etc so should not be a problem.

So other than the hubs and the calipers, carriers, hoses, pads and discs i should be ok?

Also would two pot calipers off an Audi S2 fit on the carriers? or would this be over kill for this application.

Kind Regards :-D

If you have the g60 slider pins I take it you dont need to shave anything off, I think my carriers have the slider pins

no if you have the complete g60 setup and are using the caliper and carrier from this u dont need to mod the slider pin, you only mod the slider pin when using the 16v caliper with the g60 carrier

Does this meen that golf mk3 gti carriers can be used as I believe these are also 280mm?

280mm ones should be OK yeah but stay away from late cars as these have a different setup with 288mm discs.

I think G60 and VR6 ones are the same. Not 100% sure though.

I've just got a set of calipers and carriers off a VR6 to carry out the upgrade and the guy assured me that they are the same as the G60 setup, I had a quick measure up and he seems to be correct. Will confirm once I have fitted them in the next few weeks tho.

For the mean time I'm going to refurb them to the best of my ability and I was after a bit of advice. So far I can find a 'repair kit' available off ebay from the well known 'bigg red'. This includes the rubber piston seals and slider rubbers. Do I need new bleed screws and slider pins, the originals look fine appart from the obvious grime/ corrosion.

I also wanted to know if there are any other companies offering similar repair kits for the Girling 54mm caliper?

Thanks guys

also i am fitting the golf gti16v 280mm set up but the guy i got em off dint have the hoses

so can i still use my original hoses ?