Got started on the rear brake job today... started with checking the parts I had preordered last year. Had everything but the calipers I ordered last week, or so I thought. The bearing and seal kit for the rear hubs did NOT include axle seals.

Rather than get toooo frustrated, I realized this is a first world problem, and ordered those as well.
I already got the calipers and discs off in my previous inspection to see what damages I was dealing with. So I wire wheeled the POR-15 off that I had previously put on, and removed all the nuts. Now everyone's FAVORITE! The dreaded cone washers.
I preheated one with a mag torch, if you do not have one of these, a propane torch will work just as well, it will just take longer. I found that 1.5 - 2 mins heating the cone washer where it meets the flange (not the STUD - you are not removing this) worked best.
Then I used a 4lb hand sledge and a drift. I had to make a m10x1.25 nut for the studs as I could not find an old one anywhere. After heating, I put the nut on the stud. What worked for me - 2 solid whacks on the stud, then one against the flange on either side of the cone washer. An average of 6 whacks a washer.
Then I moved to heat 2 at a time, then 3.
First side took me about 35 mins (from the time I started heating the first stud). Once I had the first side done, the second side was 2 groups of 3 and I had it done in 20 mins. You DO need to whack it harder than you think. Hence the nut on the end of the studs to protect them from flaring.
Tomorrow I will get started on removing the hubs and replacing bearings/races/seals, and of course do the emergency brake refresh while the hub is off as it is so much easier.
Oh the fun and festivities!! I am missing driving this beast around... although the TDI gets over twice the mileage so that is a plus.
