JBugs - 1963 VW Beetle - Master Cylinder & Brake Line Replacement

Our 1963 Resto Custom Beetle’s brake and suspension rebuild is nearly finished! Follow along with our tech as he installs a new large bore master cylinder to feed the 4 wheels disc brakes. During the process a direct mount brake fluid reservoir will be mounted and we’ll show you how to adapt your original reservoir to the new set up. We’ll also be replacing some brake lines and cover removing and installing a new front to rear brake line.

Intro 0:00
Brake Master Cylinder Removal: 0:47
Dual Master Cylinder Modification: 1:34
Brake Light Switch Installation: 2:30
Brake Master Cylinder Installation: 2:39
Brake Line Installation: 3:11
Front to Rear Brake Line Removal: 3:34
Front to Rear Brake Line Installation: 4:42
Brake Fluid Reservoir Modification: 5:37

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Tools used in this video:

Flathead Screwdriver
Phillips Screwdriver
Crescent Wrench
11mm Wrench
17mm Wrench
3/8" Ratchet
6" Extension
13mm Socket
Pocket Knife
Hammer
Chisel

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The parts used in this video are:

VW Dual Circuit Brake Fluid Reservoir (17-2878)

VW Brake Reservoir (113611301G)

Reservoir to Master Cylinder Brake Hose (113611801A)

Reservoir to Master Cylinder Brake Line (113611805B)

VW Master Cylinder Plug (113611817)

VW Brake Light Switch (113945515H) (x2)

VW Metal Brake Line With Fittings, 200mm (113611723A)

VW Metal Brake Line With Fittings, 425mm (113611721B)

VW Metal Brake Line with Fittings, 2180mm (211511741K)

VW Brake Line Grommets, Set of 4 (211-751)

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Videos are intended for entertainment purposes. Factory specifications should be followed when performing any task on your vehicle.

[justine]

I’m replacing the master cylinder in my 1965, how do I know what bore size that I need?

[cyprianskiba]

Are the OEM brake lines using a 10x1.0 bubble fitting?

[juanrojas]

Hi I have a 59 bug with 4 wheel disc brakes and I single master cylinder but I want to upgrade to a dual master cylinder ... are there any extra lines that need to be added ? Ty

[kgyts]

My '68 has two lines from the reservoir...

[ianp]

How was the rubber grommets put on? Were they installed before brake line swivel ends were put on or were you able to slide them over swivels prior to running them through front and rear sheet metal holes?

[crod]

Is the second reservoir needed ? Or can you just run it with the one directly on the cylinder ?

[rodolfogomez]

Why do you modify the original instalation of the master cylinder with the adaption of a second reservoir in line with the original one? I don't understand this, or is there any advantage?

[johnhirsch]

Does anyone else have a much different three way connector in the rear?

[jimhendricks]

I’m going to do this in my ‘62. I need to replace the metal lines as well. What do you recommend I get? Should I buy for a ‘62 or should I get the 66-67 brake line kit?

[ZAR]

Why wouldn't you just replace the missing spacers? Without them the frame horn and deflect and bend under hard braking. You can very easily make your own or get them from a junk yard. Interstate VW is not too far from you guys.

[angelalcala]

Hello, I have a 1967 Beetle with all four drum breaks, is it necessary for me to instal that second hole Into the reservoir and mount a new reservoir in the trunk space. Or am I able
To just use the reservoir on the master cylinder. Thank you.

[alfonsoc.]

Could you please let me know the part number for The new steel line connected to the reservoir and rubber as well. I have 1966 VW Bug and would like to change front disc brake conversion. Thank you

[cyprianskiba]

What dual circuit master cylinder did you use on this 63?

[durtyclothes]

do you have to bench bleed master cylinder?

[zacharyeskelson]

Those rear tabs are harder that that and you didn't really show it.