Brake Pads Too Big for Girling 54 Calipers

Hello, diesel drivers.

Volkswagen Golf 2 TDI AFN, 81 kW, manufactured in 1996.

Today, I went to a workshop to have my brake fluid replaced. During the process, it was discovered that the brake pads for the 239 mm ventilated brake discs and the 54 Girling calipers protrude 5 mm beyond the edge of the brake disc (I thought they would settle in when installed). The mechanic told me that I absolutely should not drive the car like that, which made sense to me. Are there brake pads available for the Golf 2 in different sizes?
What would you do if you were in my position?
Best regards.
Olli.

To deburr?
or buy a suitable one, what else is there to do - sorry.
I'll take a look, maybe I have some lying around?

Hello.

Thanks for the quick reply. I'll remove the coverings tomorrow and send you the dimensions. If you happen to have any (new) ones available, that would be great.
Good evening.
Olli.

ollli wrote:

Hello, diesel drivers. Volkswagen Golf 2 TDI AFN, 81 kW, manufactured in 1996. [...] 239 mm internally ventilated brake discs

.

Hold on... the Golf 2 was never available as a TDI, and certainly not in 1996 with an AFN engine... do you have a Golf 3?

Furthermore, the Golf III originally came with front disc brakes that were 256mm in size, later upgraded to 280mm, both internally ventilated... please clarify what modifications you have made.



It's not that they simply sold you brake pads for a Golf III AFN, and those pads don't fit the 239 brake system (which is the one you actually need to get a 110 hp TDI approved).

Hi,

Did you previously have a 13" braking system and then upgraded to the Girling system, which is 14"?
Then you should also use the brake discs from that model, as far as I know they are 256mm (13" or 239mm).

so, really...

Best regards,

Ibiza1986 wrote:

explain what you have modified

Ollli has a Golf II with a 1996 AFN engine.

ah, okay

and the brake was left at 239mm? I doubt anyone uses that size anymore...

Hello.

Thank you for your replies. I will then install different brake discs with a 256 mm internal ventilation system.
Best regards.
Olli.

Hi,

If that is indeed the cause, it would be absolutely unacceptable and dangerous shoddy workmanship in the construction.
Did you build or modify it yourself?

"Furthermore, the Golf III originally came with front brake discs that were either 256mm or 280mm in diameter, and they were internally ventilated..."

256mm discs with 14-inch wheels and a 4-bolt mounting pattern.
280, then with 5-hole (plus axis).


Best regards,

Gremlin wrote:

256mm discs with 14-inch wheels and a 4-bolt mounting pattern. 280, then with 5-hole (plus axis).

Yes, that's exactly what I meant. I'm talking about 280 tires used in conjunction with the 20-year-old GTI, but as a TDI.



For the Golf II, there are different sizes of master cylinders and brake boosters available, so a modification is definitely required.

Unfortunately, back then, VW wasn't as involved in the "one-size-fits-all" approach as it is now. For example, in my SEAT, all the braking systems, from the 239 model all the way up to the 305 Cupra R brake, use the same BKV (brake control unit) and the same HBZ (hydraulic brake booster).

Therefore, it is absolutely essential to check everything, especially the brakes, as there is no room for error when it comes to safety.



Question from above: Has everything been registered? Are there reinforced springs installed with a higher axle load capacity?

Wow, it sounds like you need different windshields .

Hello.

I have a Koni adjustable shock absorber set installed. Do you think that will be sufficient with the heavier AFN engine?
Best regards.
Olli.

Okay, you'll need to check the axle load specified in the technical report. Then, it's best to look up the rear axle load for a Golf 3 with an AFN engine, as that value can likely be used as a reference.