Brake upgrades
Get in the engine bay and you can dial out some of the play in the pedal linkage by cracking the locknuts on the pushrod and adjusting that (ISTR the offside has reverse thread so just spin the rod to add/remove tension).
All of this will cost you little £s and can seriously transform the feel and performance of the braking setup before you really get serious with changing stuff.
The 256mm conversion gives you the 16v setup (for the Scirocco and Golf) up front and does this using either Audi or Vauxhall parts. The key is finding the correct caliper carriers as they need to be sized to take the Girling 54 caliper (common as muck) yet fit onto the mk1 bearing housing. Some Audis had similar bolt spacing on their front bearing housings:
Audi 80 quattro (83 to 85)
Audi 90 5-cylinder (85 to 87)
Audi Coupe 5-cylinder (85 to 88)
And of course the (genuine) 16v GTX rocco
Then all you need is the calipers discs and pads.
It’s suggested that you get new bolts when you mount it all up, as they are high stress components, and you wouldn’t really want them failing on you at the wrong moment.
Get them from VW, they’re not that dear..
Carrier bolts – N900 689 02 (x4)
Sliding pin bolts – 321 615 141 (x4)
It’s worthwhile fitting braided flexi hoses while you’ve got it all in bits as the better ones have stainless unions (no more cursing with the crowsfoot spanners)
There’s also a way of doing it with vauxhall parts
The step beyond 256mm up front is 280mm this can be done easiest with spacers that simply offset your original caliper carriers from the bearing housing, uses the same pads as before but bigger discs.
With this you want to budget for a set of 15″ wheels if you don’t have em, as they won’t fit inside 14″
You can go up to 305mm, they will fit inside Compmotive MO’s but in reality it’d be cheaper to buy 16″ rims and live with the tramlining and crap handling ![]()
Realistically to go beyond 280mm you’d be spending your money on a rear disc conversion next, easier with mk3 gti rear calipers (they don’t sieze as much) or mk4′s if you can afford it as they’re alloy.
Then you’re into multi-piston caliper territory, good for bling and ultimate track performance, but not so kind to your pocket.
As an addition to all the above, also consider spending some time and effort in replacing the tiny 19mm drinking-straw they call a rocco master-cylinder with something a bit bigger, it’ll help reduce the pedal travel. Mk3 passats come with 22mm but you can also fit late mk2 golf valver ones quite easily as well – you will have to bend/reshape your brake lines to line it up though – some golf MC’s also have less outlets, so simply split each outlet using a t-piece -one for each circuit.
For most mk2 owners you don’t need to mess with the servo as it’s already the larger size, early mk2 and mk1 owners can upgrade to the larger 9″ mk2 servo to increase the pedal assistance. Beyond these mods you’re talking about racing pedal-boxes and taking a grinder to your bulkhead – not quite an afternoons work..
Contributor: Forum user SkyRocketeer