So i got all abs parts to fit on my jetta. Parts are quite rusty and all wear items pretty much needs replacement. They are 256 front and 226 rear, discs and pads same as mk2 i presume. What handbrake cables i can use? Beam mount is different than mk3 golf, looks like it has third bolt hole same place as mk2 just not used on passat. On another abs conversion on a coupe mk2 jetta with mk3 golf abs parts and disc beam, brake cables were too long and had to modify the sleeves. I used mk2 golf disc cables i think. Also copper lines are good or copper/nickel as a minimum?
handbrake cables same as factory gti matched to the age of your car, 1800 up to 1987 and 1600mm after. CuNiFer/Cupro Nickel/Kunifer etc brake lines are what you want ideally
All i can find is copper/nickel, i will get a roll of 10m, should be enough. Today i managed to sandblast the rear axle, if i had a huge compressor and 3-4 bags of sand it would have been done in 10minutes, but my compressor is 100l tank 350l/min, sandblaster had 100l tank and only had one bag 25kg of sand to test. Brake hoses which do i buy, passat or jetta for 256 brakes?
yeah thats the stuff I mean buy golf/jetta hoses, all comes down to where the hard lines are on the chassis legs rather than the brake system. the G60 has different hoses to the 256mm 16v, not because the calipers are in a different place but because the hard lines are
Got the brake pipe, hmm, its very stiff, did not expect to be so stiff, i can barely bend a short piece by hand. On another car used plain copper pipe and was very soft. Hope i can flare with the tool i have. Got some ATE end nuts, some clips for brake hoses end, also a bench sandblast cabinet and a bag of aluminum oxide. More money spent than i thought for just 256mm brakes, and I'm holding off on the big order with brake discs/pads, bushes, brake hoses etc. Wonder if i can use just one bush per side on rear axle and use the jetta axle support bracket. The donor car was variant so it had two bushes per side.
Managed to sandblast one caliper carrier , the sand pickup needs modifying on the cabinet because blast media does not flow well. Some more pics.
Rear axle got me thinking, if it fits. Mk2 bush length is 90mm, mk3 is 90mm but thicker. B4 passat has two 50mm=100mm bushes same thickness as mk3. If b4 axle bracket bolt holes don't match on my car i can use the original mk2 brackets with mk3 bushes, assuming axle length is the same. I have all parts blasted and painted, did three coats of paint. Upon disassembly found out 3 of 4 abs sensors are shot! Pfff, lucky me!
Fitted the front hubs with new everything, brake is good, pedal goes a little bit lower maybe because of the round metal shim between piston and pad. Used textar discs and pads. Lower ball joint same as passat. Brake hose straight to caliper, removed the little intermediate brake line.
Ok, so more work than i thought! Abs is finally on and working after much hassle. Got the parts to fit rear axle, mk3 golf bushes, mk2 brake cables 16xx mm length, used the mk2 axle brackets but the b4 passat axle was a FAIL! It pushes the wheel about 3cm to the rear, and axle main body fouls the fuel tank as its further back. The part extended is between bush and main body. Its on the car now but will have to change it. One thing to note is that the brake disk does not sit perfectly in the middle of the caliper carrier. Had to replace all four lines, flare tool worked very well, not a very hard job. Abs pump and brake servo fitted no problem, matched with mk2 pedal. A little too close to clutch cable but ok, coolant bottle moved, bolt holes enlarged. For the electrics inside the car, to the fuse panel i used an existing hole covered with a bung same as front and rear abs sensors. For front abs sensors had to make a bracket and drill a hole in the body to hold the cable bracket. After fitting and bleeding read trouble codes and got permanent 01276 - ABS Hydraulic Pump (V64): Signal Outside Specifications, at this time i was very disappointed, fuses good, motor tested on 12v was spinning i thought i need another abs unit. After removing the module again and removing the plastic cover re-soldered the motor plug connections and error was erased. Sealed the unit with rtv and put back on the car. Could not manage to remove electronic unit from valve block as one of the valve coil has stuck on the valve so had to work carefully to not brake the coil. Have a working abs light too, after trying to use a mosfet to drive the mk2 light bulb and using just an LED, the abs module puts out positive 5v when there is stored faults, gave up on those and used the passat light to drive the mk2 light bulb. Brake is soft, will have to bleed again. The way i do it is, fill the reservoir and put air pressure about 1 bar, this worked for me before.
you might need mk3 golf beam brackets, they do both have different part numbers. squinting at google image picvs it does seam like the beam hole is in a different place vs the chassis mounting holes so that would explain why the mk3 beam doesnt fit right? many people have fitted mk3 beams to mk2 no problem
No, its the b4 passat beam, they are longer than mk3 golf. All i need now is a beam with integrated stabilizer either with disk brake or drums and transfer all the new parts to. What i dont know is if all beams have the studs for abs sensor wiring or just the abs fitted ones.
ah, missread. didnt think the passat beam would fit at all, my understanding was the actual beam was wider at the mounting points. a mk3 beam would probably be best, the abs cable plastic brackets may not fit mk2. and/or if you go mk3 with abs that'll have all the stuff already on it as well
Yeah sure will get mk3 ones as they are cheap, mk2 disk were only on gti-s and any gti part costs more. Mk3 had what i need even on diesels with drum brake.
Got one cheap from a vr6 mk3 maybe. This one has 1360mm the one from the car and the passat had 1330, very nice. Now i need some good weather to sandblast and paint as it is a bit rusty. It's been raining all week, like it is in uk, he he!
Job done, mk3 axle is on the car. The usual pics, notice the difference, passat on the bottom. Beam supports seems the same fitment just more solid on mk3. One more thing to note is regarding brake hose support on the beam, mk3 has larger hole and is slotted, had to close the gap with some pliers otherwise the hose would go through.
Hi folks, I was reading through this nice conversion, I am thinking about to do this as well and at this moment collecting the info, but lost a little in the final setup here. davidut5: Which rear beam and beam bracket did you use in the end? What is the setup in the front? Does the B4 knuckle fit in the place of the mk2 one (minding a 19mm ball joint)? Thanks in advance for the answer..
Used the mk3 beam and bracket. Front ball joint same as passat, i think late mk2s have the bigger diameter, mine is a 1991 year.
up to 87 they had 17m joints, after that 19mm. all the mk2 with 256/280s were 19mm as those came in after the ball joint switch (possibly ball joints were changed to larger size because of the switch to larger brakes on 16v/g60, or just nice timing)
