Volkswagen Beetle original (1946 - 2003) - 1978 ? Brake problems

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Mon 1 Dec 2008 01:38
1978 ? Brake problems - Ladybug
I am having a terrible time with fixing my brakes.
We have replaced the Master cyl 3 times and each wheel cyl.
It still feels like there is air in the line. We have bleed the brakes so much I should invest in the brake fluid company.
We see nothing leaking.
If my husband puts a shim where the master cyl meets the peddle, they work but there is no play and we are concerned that that is putting pressure on the brakes all the time and may lock up. However they work great then. So this is telling me there is no problem with the line anywhere.
I can't believe we have had 3 bad new master cyl.
What could we be missing?
Has anyone had this trouble before?
Please help.
My husband is good at repairs so its nothing typical. Maybe something common with VWs

Edited by Dynamic Dave on 01/12/2008 at 10:17

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Mon 1 Dec 2008 17:33
1978 ? Brake problems - Chrome
I would advise against any bodges on a brake system - remove that shim and work though the system from the brake pedal to the brake shoes.

Is the car losing brake fluid? Do you have to keep topping up the mastercylinder resevoir? If so check for corroded/leaking brake lines and knackered/leaking slave cylinders in each brake drum (they push on the brake shoe cam).

Am I correct in thinking that these cars have all-round drum brakes with the possible exception of the Super Beetles?

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Mon 1 Dec 2008 17:40
1978 ? Brake problems - jc2
Some Beetles had "inside-out" discs on the front.
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Mon 1 Dec 2008 18:25
1978 ? Brake problems - Ladybug
We have replaced all the wheel cylinders and the Maser cylinder 3 times. We do not see any leaking anywhere. It is a Super beetle.

We only put brake fluid in while bleeding them. We don't see air in the line.

What is weird is when we had it shimed it held good. Good presssure. If there were any leaks in the line we still should have had the problem.

We have replaced the shoes as well.
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Tue 2 Dec 2008 08:02
1978 ? Brake problems - Chrome
The master cylinder then:

Are you using a non VW pattern part / is this the correct part?
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Tue 2 Dec 2008 08:53
1978 ? Brake problems - ausziggy
Hello all,
My first reply....but an avid reader for many years.
If you have the original rubber brake hoses still fitted, these may be the cause of the problem. Have an assistant pump the brake pedal while you feel each hose in turn for swelling or expansion particularly the front hoses.
The rear brake drums on these vehicles had a nasty habit of going "out of round" making a firm brake difficult to achieve.
I hope this helps.
Greg
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Tue 2 Dec 2008 10:02
1978 ? Brake problems - sierraman
It would be helpful to know the exact year and model,post 1969 had dual circuit brakes,so used a tandem master cylinder.1302s and 1600 had front discs.I would have thought that,by now,flexis and brake lines would have been replaced.I,too,cannot believe you have been supplied with three faulty cylinders,more likely incorrect ones.When a new one has been fitted has it been adjusted?The pedal stop plate can be moved to acheive this,1mm free play is all there should be before the pushrod hits the piston.
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Sat 3 Jan 2009 18:58
1978 ? Brake problems - Ladybug

Thanks for everyones help. My husband finally got so mad at my bug we took it to a repair shop and hoped for the best. I tried to find one that knows old bugs and I lucked out.
Come to find out, my bug was missing the shims in the firewall and that was why there was to much play. Apparently they were never there and that was why my brakes never seemed quite right!

All the stuff my husband did was good and now my brakes are great!

I hope this info helps someone else someday so they don't go crazy like we did.

Thanks everyone!
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