issues with brake rotor not fitting... 5 lug swap

hi gang,

I've been working on a 97 tdi sedan with a 5 lug suspension swapped out of a 95GLX. I've ordered the "proper" 280mm 5 lug rotors, only to find these new rotors are about 5mm's too tall, and also too thick to allow me to reinstall the pad holding bracket (sorry I forgot the name of this!)

can anyone think of what might have happened? did the PO who did the swap mix and match parts? all suggestions appreciated!

regards,
Steve

There's two versions of the 5x100 front brake setup, IIRC one uses a 280mm rotor and the other uses a 288mm rotor.

Your pads might be too thick because they were ordered for the wrong vehicle? The 4x100 'base' cars actually use a thicker pad than the GLX 'plus' suspension cars, despite the fact that the pads are identical in shape. This is the only thing I can think of about this.

I typically call the 'bracket' a caliper carrier.

Sounds to me like the 5x100 setup this car has is either 1) not from a 95 GLX or 2) it's mix n match of parts from a 280mm and a 288mm setup.

I don't remember what years the 280mm setup was used on just that it seemed to not be bounded by the 1994 MY but then again I haven't looked at brake components for a while.

Good luck

Steve

Steve is right. There are two different setups, 280 mm and 288. The calipers and caliper bridges are completely different between the two styles as well.

The 280s are made by Lucas. The 288s are ATE. The ATE 288s will have a clip on the outside to help secure the caliper to the bridge, that's the most obvious tell tale difference from a distance, anyway.

I FOUND IT!

The swap was off an early 1995GLX ... VIN up to 300000. The rotors are only 22mm thick when new. Meyle and Bremba make replacement rotors for this early setup.

Ya, I'm pretty sure the switch to the ATE 288s happened for the 96 Model year, which also coincided with a change in the entire ABS system.

95 was ATE Teves Mk4.
96 is ATE Teves Mk20.