Brake wear warning light turned on

4THA.WIN

MEMBER
2002 VOLKSWAGEN JETTA
2.0L
4 CYL
2WD
AUTOMATIC
280,000 MILES

Today I went to AutoZone and got a code read for my car. It turned out I just needed new spark plugs is what the code read. So, I went to fix them, and we unplugged the spark plug boots and tried to remove the top of where we needed to get in the engine but couldn't from lack of having the right tool. So, we figured to start again in the morning, and I was driving about 30 minutes then the brake wear warning lights and were very hard to press on. It felt like I was losing power and that the car might shut off. It also began to release a smell of something burning up. Did the boots maybe get connected wrong? Will this damage my car for good? I do not know what to do. Please help ASAP. Broke down 1,000 miles from home. Help

Tuesday, May 3rd, 2022 AT 12:11 AM

2 Replies

JACOBANDNICKOLAS

MECHANIC
110,176 POSTS

Hi,

There is a brake wear sensor one in front and one in the rear. Once the pads get thin enough, a rubber coating touches the brake rotor allowing the terminals in the sensor to touch and turn the light on.

Do you still have the smell? Could you tell approximately where the smell was coming from?

Based on your description, it wouldn't have run correctly for 30 minutes if the wiring was mixed up. On the other hand, if the brake pedal got stiff, the engine seemed to lose power, and you smelled something burning, the first thing I recommend is this.

Under the hood, and behind the brake master cylinder is the vacuum power brake booster. There will be a larger vacuum hose going to it. In theory, I suspect after work was done, something was moved and allowed that rubber vacuum hose to be damaged or melted by touching something hot. That would cause a drivability issue and the brake pedal to get very stiff.

I attached a pic below and highlighted the hose. Inspect that hose from the booster back the engine intake manifold and let me know what you find.

Take care,

Joe

See pic below.

Image (Click to make bigger)

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Tuesday, May 3rd, 2022 AT 6:30 PM

KEN L

MASTER CERTIFIED MECHANIC
54,137 POSTS

How does the engine seem to run? Also, are there any engine warning lights on? It sounds like you have a brake booster that has gone out or the booster rod is adjusted to far out. Try to loosen the brake master nuts two turns to see if the brakes release. If so, adjust the brake booster push rod inward two turns and put the brake master back on. Also, you will need new rear brake pads. This video will show you how:

https://youtu.be/31m24XZj79c

Check out the diagrams (below). Let us know what happens and please upload pictures or videos of the problem.

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Tuesday, May 3rd, 2022 AT 6:38 PM