Video: VW Super Beetle Dual Circuit Master Cylinder Installation

Video Overview:

Now that we have upgraded the VW Brakes with 4 Wheel Disc Brakes installed on our 1971 Super Beetle we need to install a master cylinder that can supply the appropriate amount of fluid to the calipers. The installation is quite simple and takes just a few tools. Bleeding the brakes afterwards will take more time but we’ll address that later as we’re going to be pulling the body off soon.

Video Transcript:

Hello! Sam here with JBugs.com. In our last two videos [we] installed front and rear disc brakes on our 1971 Super Beetle, and since we did, we need to install a large bore master cylinder. This is a must as the pistons on the caliper are much larger than the bores on the wheel cylinders, so they require more fluid in order to operate more effectively.

To start, we chalk the back end of the car, jack the front end up, and set it on jack stands. We pull off the front left wheel so we can better show the process and it does make the access easier but isn’t totally necessary.

The two brake light switch harnesses are unplugged. The front and rear brake lines are un-threaded from the master cylinder. The two reservoir feed hoses, in our case some oddly retrofitted pieces, are removed from the inlets. Since our oil fluid reservoir is empty, we don't need to worry about capping off the hoses. Make sure that you have some rags and a drain pan handy otherwise.

Inside the car, the two bolts at the left and the right of the master cylinder and the firewall are un-treaded. Then back under the car, the master cylinder is pulled from the chassis. Our new EMPI large bore master cylinder is prepped by installing two new, three-prong brake light switches. With the help of an assistant inside to guide the brake pedal pushrod into the new master cylinder, the master cylinder is slid back into place at the chassis. The two bolts inside the car can be tightened to secure the master cylinder in place.

Underneath, the two feed hoses can be reconnected to the ports on the master cylinder. The front and rear brake lines can be threaded into place. Then the two brake light switches are reconnected. Either harness can plug into either switch.

Normally, we'd now begin bleeding our brakes, but we plan on pulling our car apart so we're going to hold off on that for now. You can go back to some of our other videos where we cover bleeding our brakes if you’re unsure on how that process goes. We do have one more video planned on our car where we'll address the rear suspension before we tear it apart so stay tuned for that.

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