VW MKIV upgraded brake cable installation I got a complete kit from

VW MKIV upgraded brake cable installation
I got a complete kit from Bora. New improved (thicker) cables and all holders except the one at
the caliper because those still work.
The inside console was the worst part as expected. This car was an auto so your access to
cable
ends and adjustment in console may be different.
These cables had been changed in 2009 and here at the end of 2012 you can see they were
clearly shot.
Tools:
1. 15 torx.
2. 10mm gear wrench.
3. 13mm socket (for arm rest bolt).
4. Channel locks (for undoing/redoing cables at caliper, installing and bending
hangers).
5. 7mm deep socket (used to push new clips over the studs in the body – any size will
work).
6. Upholstery tool – I use this to try and remove the clips described above.
7. Picks were to pull out rear cup holder (which had probably never been pulled out).
8. Magnetic pickup was for the 2 torx basically inside the console under ashtray.
9. Always helps to have some light.
10. Flat blade screwdriver for only clip I reused at bottom of caliper brackets.
Here are all the parts you should receive in your kit, including upgraded cables, larger clips, and
new hangers.
Left rear caliper before starting the procedure.
The rest of the bad cable before starting.
The upholstery tool I used to undo the clip that goes over 2 studs (not shown).
Next clamp up the cable was removed (under axle beam), and last old clip is still in place.
Pulling the Left side old cable out of the tube (prior to this I had undone the end inside in the
console).
Old cable (top) and new cable (middle) for comparison. Definitely an improved part.
View under center console, showing cable ends near ebrake.
Left cable installed, right cable about to be installed. Keep adjustment as lax as possible at this
stage. 10mm gear wrench is used on the adjusting nut.
Here are the clips used under the axle beam bushing. New on the left, old on the right. I used
needle nose channel locks to smush and extract the old one and to install the new one. The last
¼ inch or so can be stubborn to get in.
The next old hanger.
Old hanger (left) and new hanger (right).
New clip (left) and old clip (right).
Cable in place at caliper. Clip not yet installed for it (these were the only clips I reused).
Before installing new cable into the clip under axle beam bushing.
Installing cable clip under axle beam bushing and getting it seated. The last ¼ inch or so will
require some persuasion.
Installing the cable into the clip. The new clip will require some effort to be put in place over the
new, thicker cables.
Installing the clip that goes over the 2 studs. Using a 6mm deepwell to push clip over studs.
Note that metal section of the cable will end up just before this clamp.
Clip installed and cable installed. Again using the socket to get it all pushed onto studs.
Using the socket to push clip over studs saves unnecessary wear and tear on fingers.
Install complete except for the only clip to be reused at the caliper.
Complete installation on left side, continued.
Forward most cable and 2 clips installed.
Left rear after I installed the clip at caliper.
End of Left Side.
_________________________________________________________________________
Right side:
Right rear caliper before starting.
Rest of right side cable before starting.
The two most forward clips before removal.
Removing right side clip.
Continued right side removal.
Continued right side removal.
Right side with all clips removed.
Another right side shot of old cable. Note swelled spot (middle).
Right cable installed into caliper. Important note: Cable was attached inside under console
before attaching this end.
New cable only connected inside and at caliper.
Here are all the tools used during the removal and installation process.
The old parts.
Both cables connected inside.
Closer shot of installed cables.
Drivers side console screw undone in foot well to allow console movement to access cable ends
(both sides must be removed).
Drivers side console screw by front of seat shown removed (both sides must be removed).
Total tools used (inside and out).
Tool Review
1. Inside picks to get rear cup holder out.
2. Magnetic pickup to get the 2 screws out under the ashtray.
3. 13mm to remove armrest.
4. 10mm for cable adjusting nut.
5. Torx for interior screws (T15).
6. Also shop light and/or flashlight as required.