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

View our complete selection of air-cooled VW parts on the JBugs website: www.jbugs.com/
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)
www.jbugs.com/product/17-2878....
VW Brake Reservoir (113611301G)
www.jbugs.com/product/11361130...
Reservoir to Master Cylinder Brake Hose (113611801A)
www.jbugs.com/product/11361180...
Reservoir to Master Cylinder Brake Line (113611805B)
www.jbugs.com/product/11361180...
VW Master Cylinder Plug (113611817)
www.jbugs.com/product/11361181...
VW Brake Light Switch (113945515H) (x2)
www.jbugs.com/product/11394551...
VW Metal Brake Line With Fittings, 200mm (113611723A)
www.jbugs.com/product/11361172...
VW Metal Brake Line With Fittings, 425mm (113611721B)
www.jbugs.com/product/11361172...
VW Metal Brake Line with Fittings, 2180mm (211511741K)
www.jbugs.com/product/21161174...
VW Brake Line Grommets, Set of 4 (211-751)
www.jbugs.com/product/211-751....
All parts used in this video are available at: www.jbugs.com/
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Music Provided By:
Keep It Real by Audionautix is licensed under a Creative Commons Attribution license (creativecommons.org/licenses/...)
Artist: audionautix.com/
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Videos are intended for entertainment purposes. Factory specifications should be followed when performing any task on your vehicle.

[@dunebuggy1286]

I wish I had this video 15 years ago.

[@Sam_Mebane]

Hopefully you got it figured out! The first time I did a front to rear brake line was in the dark, with a flashlight under a rain soaked 1970 Beetle, not exactly fun but I managed.

[@emadvolkswagenrestoration88]

good job

[@djjonnybong]

Awesomeness

[@fabribunny4639]

tanck !!

[@jimhendricks4394]

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?

[@JBugsVWParts]

The front left and right steel lines in the 1967-68 kit are 40mm(1 5/8”) and 125mm(4 7/8”) longer than the 1958-66 kit. The additional length of the kit ( www.jbugs.com/product/113698001A.html ) will make installing a dual circuit master cylinder a bit easier, yes.

[@ianp6540]

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?

[@Sam_Mebane]

The rubber grommets are split so they can be installed whenever you get to them.

[@johnhirsch9]

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

[@JBugsVWParts]

We aren’t familiar with any other sort of brake line tee but perhaps others may offer some suggestions. Brake Line T - www.jbugs.com/product/113611755.htmlIRS cars run a junction fitting on the opposite side if that’s what you’re referring to www.jbugs.com/product/113611791.htm

[@alfonsoc.2291]

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

[@JBugsVWParts]

The steel line is www.jbugs.com/product/113611805B.html, the rubber hose is www.jbugs.com/product/113611801A.html

[@alfonsoc.2291]

JBUGS great thank you also I forgot to ask the part number for the 2 bolt you put on the master cylinder for the brake line. Minute 2:34

[@JBugsVWParts]

The two bolts that were installed onto the master cylinder are actually brake light switches. The VW 2 Prong Brake Light Switch threads into the master cylinder and operates the brake lights. They can be found here www.jbugs.com/product/113945515H.html

[@rodolfogomez382]

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?

[@JBugsVWParts]

1966 and earlier Beetles have a feed to the single circuit (one chamber which operates both front and rear brakes) master cylinder. We swapped out to a later model style, dual circuit master cylinder (one chamber for the front brakes and one chamber for the rear brakes) which requires 2 feeds.

[@juanrojas4722]

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

[@JBugsVWParts]

We converted our 1963 Beetle to a large bore dual circuit here: kzbin.info/www/bejne/eaDVm52uj5yaiK8 which covers the upgrade.

[@justine9980]

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

[@Sam_Mebane]

If your brake system is stock, use a stock replacement. If you have disc brakes, you will want a larger bore master cylinder.

[@cyprianskiba8768]

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

[@Sam_Mebane]

Yes, that is the stock brake line size.

[@kg7yts187]

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

[@Sam_Mebane]

Yep, starting in 1967 VW went to a dual circuit (one for the front, one for the rear) master cylinder so they all have 2 lines from that point on.

[@cyprianskiba8768]

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

[@JBugsVWParts]

Click the “SHOW MORE” button above to see all the tools and most importantly the parts used in any of our videos. The master cylinder is the VW Dual Circuit Brake Fluid Reservoir (17-2878) www.jbugs.com/product/17-2878

[@mrrawbacon]

@@JBugsVWParts Am I missing something? There is no part number listed under show more for the actual master cylinder

[@durtyclothes]

do you have to bench bleed master cylinder?

[@JBugsVWParts]

No, there is no need to bench bleed the master cylinder. Pressurizing, or vacuuming out the system is required though. Otherwise the brakes will not build up pressure.

[@durtyclothes]

just bleed the brakes then, after installing the new cylinder ?

[@JBugsVWParts]

Yes, whenever there is a change in any brake component, always bleed the brakes.

[@crod1449]

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

[@Sam_Mebane]

You can use just the one on the cylinder but filling it can be difficult.

[@angelalcala2791]

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.

[@Sam_Mebane]

A 67 Beetle has a dual feed reservoir from the factory, so you can use it, or a stock replacement.

[@ZAR66]

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.

[@JBugsVWParts]

As the car will be coming apart for paint and body work, we aren’t too concerned with the spacers. Normally we would have made some spacers, but in the midst of our warehouse “garage” we don’t have the access to all the tools and scrap metal we have in our actual garages. We mention it for those that do, but it isn’t the end of the world and we’ve driven dozens of cars without the spacers in place.

[@zacharyeskelson6229]

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

[@JBugsVWParts]

Some can be more difficult than others, absolutely, none have been impossible. It just takes some prying and a bit of leverage so we didn’t see a need to cover it in detail.

[@zacharyeskelson6229]

JBUGS I apologize it was completely my cars brackets. They were bent which made them near impossible. I guess I was just jealous yours were easy. My bad.