When we bought our Volkswagen Bay Window Type 2 back in April, 2020, we had the not-so-pleasurable experience of the bus pulling harshly to the left when applying the brakes. We poked around on the ultimate forum for all things VW Type 2, TheSamba.com, and the recommendation was that a full brake inspection and refresh should be the path forward.
We took off the front wheels of the bus to reveal the front disc brake calipers, and all looked well. The calipers and discs appeared in great shape, though dirty from years of non-maintenance from the previous owner. After a general cleaning of the front brake area, we moved to the rear brakes.
For the rear brakes we mistakenly believed that we had to take the large center axle nut off to remove the brake drum. This was not case and we wasted at least an our looking for a socket big enough, and then trying to apply enough pressure to move the stubborn nut. We then discovered that by removing the two, small drum screws, and adding a few light taps with a rubber mallet, the drums reluctantly shimmied off the axle, leaving the large axle nut in place (you live and learn). On drum removal, judging by the cobwebs the drums had been untouched for quite some time.
On to the brake components themselves. Though not completely worn, the brake shoes had deep burrows across the brake shoe media and also seemed to only be applying pressure to certain areas of the drum. More concerning was the amount of damp "mud" that covered the inside of the drum and the brake cylinder. Yes. the brake cylinder was leaking, mixing with drake dust, and creating a mud-like substance that covered the internals of the drum.
The only safe option was to perform a full brake refresh to both rear wheels. To do so, we took pictures of everything so that we could replace the parts and apply the same hook-ups for springs and levers - it gets a little complicated. Surprisingly, our local O'Reilly's auto store had two brake cylinders and a set of shoes for the princely sum of $50 - what a deal! Ideally, we would use quality VW parts but we figured new, aftermarket parts HAD to be better than the 44 year old leakers we were currently sporting.
The drum-plate were stripped of shoes, springs, and cylinder and cleaned the back-plate with a brake cleaner product. One caveat is the removal of the existing brake pipe. Aging brake pipe nuts/unions are notorious for splitting at the brake pipe when pressure is applied to the nut. These brake nuts have possibly sat in the same position for decades and are reluctant to move and so twist the pipe with the nut. To overcome this issue, we soaked the brake nuts in PB Blaster and returned an hour later. Then we applied a small amount of heat and used a crescent wrench; a wrench that grabs 75% of the brake nut, and so lessens the likelihood of the nut twisting the brake pipe. The process worked a treat and the brake pipe came off both cylinders with no issues.
Next issue was the brake adjusters. The 1976 Volkswagen Bay Window Type 2 has its brakes adjusted via "peepholes" in the brake back-plate. This allows adjustment of the brakes without having to remove the brake drums. Unfortunately, in an attempt to adjust seized adjusters, our glorious previous owner had gouged the peepholes into twice there original size. We took the seized adjusters apart by heating them and applying trusty PB Blaster. When apart, we then cleaned and reassembled while applying a little anti-seize paste. The adjusters now adjusted and required little force to do so.
After replacing the brake cylinder, shoes, adjusters, and springs, the brake system looked strong and reliable. No more leaks and fresh brake media. We applied the same attention to both sides of the rear brakes. For even braking, it's always a good idea to refresh both sides of the braking system at the same time.
When the work was complete, we bled the rear brakes and went on a test drive. Awesome! The bus now stops straight and true. So for $50, and an afternoon of our time, our brakes felt strong and reliable. We now have confidence in our bus's braking system and are fully aware of the condition of all braking media and braking hydraulics - priceless!
Again, if attempting such a brake refresh, take pictures of everything. There are a number of springs and parking brake levers that must be replaced in the same orientation as they were removed.
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