The rear brake caliper dust boot cannot replace?

Tiny
PHILIP GAO
  • MEMBER
  • 2012 VOLKSWAGEN ROUTAN
  • 3.4L
  • V6
  • 2WD
  • AUTOMATIC
  • 160,000 MILES
Yes, the simple way for this problem is totally change two rear brake calipers. But I tried to rebuild it first, the caliper got stuck and moved difficult, I tried to fully open it and clean inside the caliper, the dust boot broke when open the caliper.
I have bought 3 caliper repair kit, but all the size can't match.
Pic1: the dust boot in the picture
Pic2: the general caliper piston part picture, the open hole is a simple circle
Pic3 my caliper, the piston open hole is special two edge
pic4 the caliper repair kit

The original dust boot is a soft base ring, locked in the open hole second edge, I don't have the photo, but the repair it is a hard base rubber ring, someone said there is a steel ring inside the rubber

The piston first inner diameter is 51mm.
The piston second outer diameter is 55mm.
The rubber dust inside diameter is 50mm.
The rubber dust outside diameter is 55mm, see the pic 5.

It looks like I can't install this, any idea?
The rubber only press the outside diameter to 51mm or extend the inside diameter to 55mm, otherwise I can't install it back, but there is steel ring inside the rubber, I can't change the size like this.
Wednesday, July 20th, 2022 AT 2:09 PM

7 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 42,884 POSTS
It looks like you have the wrong caliper rebuild kit, here is the correct part number and instructions for how to rebuild the caliper in the diagrams below.

Right Caliper 7B0615424C $78.00
Left Caliper 7B0615423C $73.00

Check out the diagrams (below). Let us know what happens and please upload pictures or videos of the problem. They only show the front brake caliper rebuild but it should be very similar to the rears.
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Thursday, July 21st, 2022 AT 11:25 AM
Tiny
PHILIP GAO
  • MEMBER
  • 13 POSTS
Thank you, Ken, finally, I gave up to seek a dust boot, bought a pair of rear calipers as replacements. It's not easy to find the small piece in North America. Maybe the brake hose should change together, it has 10 years now. Blessed and be in Peace.
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Wednesday, July 27th, 2022 AT 9:26 AM
Tiny
KEN L
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Tubes and Hoses Inspection.

Brake tubing should be inspected periodically for evidence of physical damage or contact with moving or hot components.

Flexible rubber hose is used at both the front and rear wheel brakes. Inspection of the flexible brake hoses should be performed whenever the brake system is serviced and every 12,000 km (7,500 miles) or 12 months, whichever comes first. Inspect hydraulic brake hoses for surface cracking, scuffing, or worn spots. If the fabric casing of the hose becomes exposed due to cracks or abrasions in the hose cover, the hose should be replaced immediately. Eventual deterioration of the hose can take place with possible burst failure. Faulty installation can cause twisting, resulting in wheel, tire, or chassis interference.

This vehicle is equipped with more than one size (diameter) brake tube depending on the location on the vehicle. If a brake tube must be replaced, always use the same size brake tubing as that being replaced. Never use under-size brake tubing.
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Wednesday, July 27th, 2022 AT 1:01 PM
Tiny
PHILIP GAO
  • MEMBER
  • 13 POSTS
Greetings!
The new calipers deliver fast. But the problem comes fast too
I found the new one can install in the same place, because the distance of the caliper adapter mounting bolts is the same at around 140mm.
But the new caliper has a shorter size brake pads room, my previous one is 130mm, the new one is 115mm, it's really crazing I can't find a place to sale the brake pads according to the size, I searched the VW deal site but found nothing.
Guess the new caliper dealer said this one does not match the heavy-duty caliper, my one is possible this type.
My choice:
1) Find the correct brake pads to match the 115mm new caliper room.
2) Return the new caliper, continue to look for a duct boot, if you really can't find one, use some rubber to cover it better it in bare.
Thank you, Ken, for giving me the model's name: Right Caliper 7B0615424C $78.00.
But I can't find the size or same number with my old one. Only from the sale's web site picture, I can't confirm this.
Could you tell me the correct pads is what model? Or any wisdom idea? :)
Thank you!
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Thursday, July 28th, 2022 AT 7:58 PM
Tiny
KEN L
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Sure,

Caliper - 7B0615424C $78.00 Left
Caliper - 7B0615423C $ 73.00 Right

Rear Pads - 7B0698451B $49.00

Check out the diagrams (below). Please let us know what happens.
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Friday, July 29th, 2022 AT 1:42 PM
Tiny
PHILIP GAO
  • MEMBER
  • 13 POSTS
I have bought 8 wrong caliper rebuild kits, finally, I find this parts: 68144207AA
https://www.bitautomobile.com/chrysler-brake-caliper-68144207aa-product/
This caliper's piston diameter is 45mm, this caliper match my van
I try find the 68144207AA caliper's rebuild kit
this one maybe is correct:
https://www.zeckhausen.com/catalog/product_info.php?cPath=13_3576_1316_5686_5688&products_id=25464
it for 45mm piston Caravan 2012, I can't find the VW routan parts(2013 Routan include this parts, maybe some mistake in Volk data), this one should be more close
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Saturday, September 2nd, 2023 AT 4:41 PM
Tiny
KEN L
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I am glad you found the correct parts. Please let us know if you need any more help.
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Sunday, September 3rd, 2023 AT 10:32 AM

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