Tried to change discs and pads today but stuck at the first hurdle, the M8 capheads are stuck solid and the 6mm allen is just chewed out, even a 1/4" wont "bite" when hammered in, they refuse to budge at all which as you can imagine has pleased me to no end.

Anything I can do to overcome this problem with basic tools? I don't have a welder to attach a nut and there isnt the room to try and hammer a socket on :(

Things I have tried

WD40, Hammers, slightly larger allen keys, Flat Bladed bits hammered in, torx bits hammered in, moving the caliper around so as to relieve any tension, all with no luck,

I'll definately have to replace the bolts, would I get away with standard M8 x 50mm and 60mm or do I need the specific VW part?

This is the first time I've changed brakes on a VW and have to say, I'm not pleased, with not just use normal 13mm hex bolts like most people??

What I've done in the past is remove the sleeve covering the bolt and hammer on a 12mm 12 point socket.

They are a perfect fit and work everytime.

As for replacing the bolts you can get rebuild kits on ebay for the calipers which come with new bolts and sliders. Or you could try a scrappy.

Thanks mate will give that a shot, which rebuild kit am I looking for?

http://www.ebay.co.uk/itm/VW-POLO-2001-2009-FRONT-BRAKE-CALIPER-SLIDER-PIN-KIT-GUIDE-BOLTS-BCF1314B-/331288113039?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item4d224f6f8f

should be a kit like this avail for you car /year

I had the same problem recently and used these (Laser part number 4016)

Grips the end of the bolt/pin and it came out no probs

Thanks for the advice chaps, Nige they look fun! haha

I was a bit dubious of them but it worked a treat :)

If you need the bolts etc I have all the bits I stripped off a used set of callipers which got thrown away, so it's all the rubber bits and sleeves as well as bolts etc. Pm me if you want them

Nige, would they work on the heads of the cap head screws on the calipers?

Just want to make sure before I buy them

Mole grips on those bad boys and abit of heat!

irwin bolt grips would grip on those

The pins on mine didn't look as bad as yours, all the normal methods failed but they worked, might need to soak some penetrating fluid ( not wd40!) before ?

haha that's reassuring, and that was the better of the two!

Struggling to find a kit, either I'm using the wrong terminology or VWII/Bendix kits aren't all that common?

anyhow, found this - http://www.ebay.co.uk/itm/191213912004

Looks like its the one I need, awaiting their confirmation!

I really begrudge letting the garage take to it, they'd only bodge it if their past work is to be gone by, and charge me full whack for it too, but alas if I cant do it, I may as well pay top dollar at the dealership garage instead!

Angle grinder, two flat edges, plus gas overnight soaks, mole grips, hammer.

Do not let a stealership take your money! Everytime I've taken my car there they break something and then bodge it and tell me it was like that! FFS.

Good luck.

PoloD.

Edited 1 December, 201411 yr by PoloD

That is the correct item (post #13) going on the OEM numbers in their listing

Thanks nige! your a beast haha

Well I'm not having much luck, the seller said they are for earlier models and not my type, I should clarify these are Bendix VWII calipers incase you were unsure nige... going to ring VW up and have a word..

Bolts are £1 each, Metals Sleeves around £7 each,

he said a kit with plastic tubes and what not is £20 each, but the dont come with bolts and sleeves...

£80 because of some chewed out heads!! bloody hell!

Edited 2 December, 201411 yr by R10tz0r

brake caliper housing / Brake Disc (vent)

BENDIX 239X18MM /

1 6N0615123B

brake caliper housing

left /

(1) 6N0615124B

brake caliper housing

right /

2 171615221

guide sleeve

45MM /

3 171615221A

guide sleeve

35MM /

4 N 90329104

allen key head bolt

M8X49 /

5 N 90329205

allen key head bolt

M8X59 /

6 6N0615311A

splash shield for brake disc

left /

(6) 6N0615312A

splash shield for brake disc

right /

7 N 90529301

hexagonal head bolt

M6X10 /

10 357615273

bleeder valve

M10X1 /

(11) 6N0615301C

Brake Disc (vent)

239X18 4/100 /

12 N 10112603

countersunk bolt

M6X15SP /

13 211611483

dust cap

/

15 6N0698151

1 set: brake pads for disc brakes / for models without anti-locking system

/

(15) 6N0698151C

1 set: brake pads for disc brakes / for models with anti-lock brake system -abs-

/

16 171698447A

1 set: guide bushes

/

17 171698471B

set of seals for brake caliper housing

/

18 6E0615193

air guide

left /

(18) 6Q0615194

air guide

right /

19 N 01021226

hexagonal head bolt

M6X12 /

#16 is the part number shown in that ebay link

ahh right, if thats the case then, I'm gonna purchase that kit and forget silly prices at VW LOL

Thanks nige

Well, little update, that kit is for a non vented 10mm disc setup, mine is the 18mm vented setup.....

back to square one, rang up VW to confirm part numbers and he wouldnt give me them... idiot

The listing said it was equivalent to item # 16 and that is for the vented discs ???

I think their listing is wrong because I asked for a list of equivalent parts in the kit and the parts he came back with match up with the non-vented disc (2x 104 bolts, 2x 221A sleeves)

I need the following

171615221 Guide Sleeve 45mm x1
171615221A Guide Sleeve 35mm x1

N90329104 Socket Head M8x49mm x1
N90329205 Socket Head M8x59mm x1

171698447A Guide Bushes Set x1

it's shit like this that makes me hate car manufacturers haha

Have a look on "Big Red" brake site, they do the complete slider kits

X2 for biggred, sure you may be able to get all the bits cheaper if you source them separately, but they send you one kit with everything. I have just received there rear calliper kit today and it's very good. Turned up next day too.

Thanks guys, got in touch with a different seller on ebay with a similiar kit that looked like the one I needed (different length bolts) but he advertised it as only for Kelsey Hayes calipers, so I sent him a message regarding the components in the kit, and he responded saying the Kelsey Hayes are also marked up as Bendix or even ATE but their style is the exact same, which makes me very happy indeed, just awaiting confirmation on vented disc compatibility, but I think I've got it!!