Oichan's Corrado Non ABS Brake Swap Mod


Non ABS Brake Swap Mod! 2005/10/31 I experienced that the brake pedal's feel became bad(spongy feel) at the race track many times. It occurs in case of the overheat by the traffic jam, too. I did the determination which says good-bye to ABS.

	An ABS control units connecters terminal was corroded by the cooling water invasion to along the wiring. The ABS control unit doesn't work! I recommend to inject a caulking into the wiring connector of an ABS control unit.
	I got this master cylinder w/ plug and etc from the Yahoo auction. 357 611 019 B Master cylinder for non-ABS 18,700yen 357 611 243 Gasket 680yen 443 611 190 Plug 930yen 357 611 817 Plug 920yen
	Brake servo from '87 GolfII GTI(parts car) 357 612 107 A Brake servo 36,300yen.
	Heat protecter for brake servo 357 612 163 5,200yen
	Brake fluid reservoir 1H1 611 301 A 7,300yen
	Brake fluid reservoir cap w/ Fluid level sender 1H1 611 349 2,000yen.
	357 612 209 A It's brake servo and clutch master cylinder bracket. I got it from German friend Michael on October 12th. about 50 dollars w/ shiping. There is VW dealer in the opposite side at his work place.
	In the first thing, Re- paint the brake servo to black color. Like a new one!
	Remove the dash under tray of the driver side.
	Loosen three nuts of an ABS unit bracket. But, It is difficult to access nut of the upper side.
	I used the long extension(about 40cm) on a socket and universal for loosen top nut. It is difficult to loosen because the nut head has white paint. Why is it painted? mad!
	Loosen one nut of an ABS unit bracket near clutch master cylinder push rod.
	Remove lock washer of lock pin from the brake pedal and clutch pedal.
	Remove the strut tower bar and cooling reserve tank... etc for making a work room.
	enough?
	Remove clutch master cylinder mount nuts.
	Remove brake hard line and harness connector and drain brake fluid.
	Removed The ABS unit weight is 12 kg.
	All non-ABS system's weight is 5.0kg. Reduced weight 7.0kg :D

	Install the bracket to the brake servo.
	Install the master cylinder to the brake servo.
	The master cylinder have a four brake line holes. But Corrado have a three brake lines, two front brake lines and single rear brake line. It's a plug for one brake line hole.
	Tighten up a plug with the flat head screw driver.
	Install three brake lines to the brake master cylinder. It was easy to bend the hard lines of the brake by my hands. But, bend it carefully, it break easily. I think!
	Install the brake fluid reserve tank to the master cylinder. Use the lubrication oil (included to the reserve tank) and push it into the master cylinder.
	It's the brake fluid reserve tank lock pin and lock washer.
	Lock the brake fluid reserve tank with the lock pin like this.
	Connect the brake fluid reserve tank to the clutch master cylinder w/ hose.
	Connect the vacuum hose from the intake manifold.
	Fill the brake fluid and bleeding brake and clutch.
	Reassemble many parts like this. :D The reason for swapping broken ABS system to non-ABS is the non-ABS system is much cheaper to replace. I swapped to non-ABS because a new ABS system is $3,050 in Japan. The entire non-ABS setup cost is under $400.
	06/11/2005 I felt bad pedal feel, I still have a little air in the rear brakes, an air bleed again. Recently, the grayness increased to my hair. :-(
	09/07/2006 I added the brake pressure regulator to the brake line of non-ABS master cylinder for the rear brake. Because, I don't want spinout again! Parts # 191 614 163 A I got this pressure regulator from the stock ABS unit.

Back