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Its not the actual head diameter that controls the range of adjustment, it is totally controlled by the offset between the head & shaft centers, 5mm of offset will give a 1 centimeter range of travel.
The disc brake conversion will fit to your G2 Syncro whichever (68mm or 72mm bearings) rear arms you have, so you do not need to swap them over for Rallye ones.
To replace rear drums with 239×10 discs,
1) 2 of brake discs p/n 811 615 301, this is actually the same disc as fitted to the golf 2 1050cc front wheels,
or you can fit the 239×12 mm front discs as fitted to the Golf 2 1300cc to 1800cc models (55 to 90 bhp) to the rear of your Syncro, P/N 321 615 301
You will need to space the caliper carriers out from the swing arm (as the brake disc less offset) I find that the Golf 2 Diesel exhaust manifold washers are ideal for this P/N – N 900 955 01 (4 of)
2) 2 of calipers p/n 535 615 423x left and 424x right, these are the same as fitted to the rear on a gti 16v and most other vw rear disc applications of that era,
or you can use Golf 4 aluminium calipers also fit and do give better performance and have the bonus of a none seizing handbrake mechanism,
Golf 4 Calipers p/ns 1H0 615 423B left & 424B right, you will need to modify the brake pipe caliper end as the G4 uses a different fitting, but its not difficult all you need a male to male adapter piece.3) 2 of Caliper carriers are p/ns 191 615 425a left and 426 right, and have been fitted to all car type syncro rear discs from 1985 to 1998 thats the Golf, Passat and Jetta,
4) 2 of Golf Rallye cables, p/ns 191 609 721H left & 721K right,
This may help http://www.vwsyncro.co.uk/data/forums/topic.asp?TOPIC_ID=119
These are the Rallye Golf Disc brake Handbrake cables
P/N 191609721H left hand & P/N 191609721K right hand
They are available at VW classic parts
http://www.volkswagen-classic-parts.de/bestand/index_e.html
Hurrah. yes they are available at VW classic parts
http://www.volkswagen-classic-parts.de/bestand/index_e.html
P/N 191609721H left hand & P/N 191609721K right hand
It wont make any difference, but you can if you wish buy Golf 3 VR6 Syncro 5 hole rear discs P/N 1H0 615 601
You can redrill the 4 hole discs to 5 holes!
http://www.vwsyncro.co.uk/data/forums/topic.asp?TOPIC_ID=2853&SearchTerms=stud
Scroll about 1/2 way down on the first page. [
]Have you read this thread? – http://www.vwsyncro.co.uk/data/forums/topic.asp?TOPIC_ID=119
The standard Golf & Passat rear disc is p/n 811 615 301, this is actually the same disc as fitted to the Golf 2 1050cc front wheels,
You can also fit the 239×12 mm front discs as fitted to the Golf 2 1300cc to 1800cc models (55 to 90 bhp) P/N 321 615 301 to the rear of your Syncro,
You will need to space the caliper carriers out from the swing arm (as the brake disc less offset) I find that the Golf 2 Diesel exhaust manifold washers are ideal for this P/N – N 900 955 01As you state you obtained your rear axle set up from Canada I presume that its the Passat version?
Thats the one with the bolt in crossbar (that runs through the spare wheel well?) for hanging the center rear diff mounting?
if so this is not compatable with any Golf Syncro fuel tank, so most people then use a fuel cell.
There are your carriers, you can use Golf mk 2 to mk 4 or Passat rear calipers.
The captive nuts are classed as part of the bodyshell & are not listed seperately in ETKA,
The nuts should be able to stand tapping out to 9mm, try it & see you have nothing to lose by trying!
also depending on how damaged the thread is? you may find that new M8 bolts will fit tight enough in the old threads, and even better if you loctite them.
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