What size star bit do i need to remove the front brake caliper mounting bracket bolts on my 2002 Peugeot 406

On the back side of the brakes, will be 2 bolts attached to steering knuckle. You have 2 ways to remove it. You can take the 2 bolts that hold the caliper onto the caliper mounting bracket, usually a rubber boot on them, then remove the caliper. At that point, you'll have easier access to the 2 remaining bolts that screw into the knuckle. The other option is just remove the whole assembly, remove the 2 bolts in the mounting bracket to remove the whole thing.

Remove the lower brake caliper mounting bolt holding the brake caliper to the caliper bracket with a socket wrench. Pivot the bottom of the caliper upward away from the bracket to access the brake pads. good-day!

Brake Pads Removal & Installation Front

To Remove:

1. Drain brake fluid to ½ full level in reservoir.
2. Remove the front wheels.
   
   
3. Remove the front brake caliper assembly.
4. Remove the 2 anti-squeal shims from each of the 2 brake pads.
5. Remove the wear indicator from each of the 2 brake pads.

To Install:
NOTE: When replacing worn pads, the anti-squeal shims must be replaced together with the pads.

1. Using a large C clamp or equivalent press piston into the caliper.
2. Apply disc brake grease to the inside of each anti-squeal shim.
3. Install the anti-squeal shims on each pad.
4. Install the pad wear indicator clip to the pads.
5. Install the pads with the pad wear indicator plate facing upward.
6. Install the brake caliper with the 2 mounting bolts. Torque the bolts 25 ft-lb (34 Nm).
7. Install the front wheels.
8. Fill the master cylinder with new clean brake fluid.
9. Pump the brake pedal several times to seat the brake pads.

Rear TMC made rear brake components

TMMK made rear brake components

To Remove:

1. Drain the brake fluid to ½ full level in reservoir.
2. Remove the rear wheels.
3. Remove the caliper slide pins.
4. Remove the caliper slide pin bushings (TMMK made) (Kentucky).
5. Remove the rear brake calipers.
6. Remove the 2 brake pads with the anti-squeal shims.
7. Remove the anti-squeal shims and pad wear indicators from brake pads.

To Install:

1. Using a large C clamp or equivalent press the piston into the caliper.
2. Coat both sides of the outer anti-squeal shim with pad grease.
3. Install anti-squeal shims to each pad.
4. Install wear indicators on the 2 brake pads.
5. Install the caliper slide pin bushings (TMMK made) (Kentucky).
6. Install the rear brake caliper with the slide pins. Torque the slide pins as follows:
   • TMC made (Japan): Torque the caliper slide pin 25 ft-lb (34.3 Nm)
   • TMMK made (Kentucky): Torque the caliper slide pin 34 ft-lb (47 Nm)
7. Fill the master cylinder with new clean brake fluid.
8. Pump the brake pedal several times to seat the brake pads.
9. Install the rear wheels.

Brake Rotor Removal & Installation Front To Remove:

1. Remove the front wheels.
2. Remove the front brake caliper assembly.
3. Remove the front brake pads.
4. Remove the 2 bolts and caliper mounting bracket.
5. Place match marks on the disc and axle hub.
6. Remove the front wheel disc.

To Install:

1. Align the match marks and install the front disc.
2. Install the brake caliper mounting bracket. Torque the bolts 79 ft-lb (107 Nm).
3. Install the brake caliper. Torque the bolts 25 ft-lb (34 Nm).
4. Install new gaskets and connect the brake hose to the caliper with the banjo fitting bolt. Torque the fitting bolt 22 ft-lb (29.4 Nm).
5. Fill the reservoir with brake fluid.
6. Bleed the brake system.
7. Install the front wheel.

Rear To Remove:

1. Remove the rear wheels.
2. Remove the brake caliper assembly.
3. Remove the brake pads.
4. Remove the 2 bolts and the caliper mounting bracket.
5. Place match marks on the disc and axle hub.
6. Remove the rear disc.

To Install:

1. Align the match marks and install the rear disc.
2. Install the rear brake caliper mounting bracket. Torque the bracket bolts as follows:
   • TMC made (Japan): Torque the bracket bolt 46 ft-lb (61.8 Nm)
   • TMMK made (Kentucky): Torque the bracket bolt 34 ft-lb (47 Nm)
3. Install the rear brake caliper with the slide pins. Torque the slide pins as follows:
   • TMC made (Japan): Torque the caliper slide pin 25 ft-lb (34.3 Nm)
   • TMMK made (Kentucky): Torque the caliper slide pin 32 ft-lb (43 Nm)
4. Install new gaskets and connect the brake hose to the caliper with the banjo fitting bolt. Torque the fitting bolt 22 ft-lb (29.4 Nm).
5. Fill the reservoir with brake fluid.
6. Bleed the brake system.
7. Install the rear wheel

Disc Brake Pads for Suburban 1500 Removal & Installation Front To Remove:
Front caliper mounting bracket

1. Remove the cover on the master cylinder and siphon out 2/3 of the fluid. This step prevents spilling fluid when the piston is pushed back into the caliper bore.
2. Raise and support the vehicle safely.
3. Remove the wheel and tire assembly.
4. Compress the brake piston back into its bore using a C-clamp.
5. Remove the 2 caliper mounting bolts. Lift the caliper off the rotor.
6. Remove the inboard and outboard pad.
7. Remove and discard the anti-rattle clips.

To Install:
Caliper bracket sleeves

1. Thoroughly inspect, clean and lubricate all caliper slide points, bolts and hardware.
2. Install new anti-rattle clips.
3. Position the inboard and outboard pads into the support bracket
4. With the 2 pads in position, place the caliper over the brake rotor and align the holes in the caliper with those of the mounting bracket.
5. Install the caliper mounting bolts through the sleeves in the inboard caliper ears and into the mounting bracket.
6. Tighten the mounting bolts to: 80 lb. ft, (110 Nm).
7. Install the tire and wheel assembly. Lower the vehicle.
8. Add fluid to the master cylinder reservoirs so they are 1/4 in. (6.35mm) from the top.
9. Test the brake pedal by pumping it to obtain a hard pedal. Check the fluid level and add fluid as necessary.

Rear To Remove:

1. Remove 2/3 of the brake fluid from the master cylinder.
2. Raise and safely support the vehicle.
3. Remove the wheel and tire assembly.
4. Remove the brake caliper mounting bolts. Suspend the caliper from the frame with mechanic's wire. Do not allow the caliper to hang from the brake hose.
5. Remove the brake pads from the caliper mounting bracket.
6. Remove and discard the anti-rattle clips.

Rear brake caliper

To Install:

1. Install new anti-rattle clips.
2. Position the brake pads to the caliper mounting bracket.
3. With the 2 pads in position, place the caliper over the brake rotor and align the holes in the caliper with those of the mounting bracket.
4. Install NEW caliper mounting bolts. Tighten to: 30 lb. ft, (40 Nm).
5. Install the wheel and tire assembly.
6. Lower the vehicle.
7. Refill the master cylinder to the proper level with fresh brake fluid. Pump the brake pedal slowly and firmly to seat the brake pads. Burnish the brakes as needed.

The pads are mounted to the caliper. The caliper is bolted to the spindle bracket. There is brake hardware which should be replaced with the pads.
Look behind the wheel at the backside of the spindle bracket. The spindle bracket is on the verticle shaft with coils on one end and an A shaped bracket on the other. There are usually 2 bolts that may have normal bolt ends or "Allen" bit fittings.

When you buy the brake hardware you can check for the proper socket for the mounting bolt. You unbolt the caliper, use a rope or wire to suspend it under the frame without disconnecting the brake line.

The pads come off with the hardware. You need to compress the caliper pistons to make the new pads fit. Use a C clamp and an old pad to squeeze the pistons back into the caliper. Remove the Master Cylinder cover so fluid can return.

Then use a bonding chemical like "brake quiet" to mount the rear pad to the caliper piston. Mount outside pad to caliper and then slide caliper over the rotor on the spindle bracket. Lube the slides of the new brake hardware and bolt into place.

You should have the rotors checked for thickness and whether they are warpped before you put on the new pads.

There are two different types of calipers used on 01 Beetles.
The first which does not have a detachable caliper bracket is easiest and is as follows:
Remove front wheels
Unbolt calipers from integrated spindle/bracket with proper allen bit and lift calipers and pads and support them.
Remove set screw holding rotor to hub. You may need an impact screwdriver as these seize up with age.
Slide rotor off hub.

The second has a separate detachable bracket that wraps around the rotor.
Remove the front wheels
Remove two caliper bracket bolts holding bracket, caliper and pads onto rotor as a unit.
Some vehicles have a standard bolt in this position, some have a VW special star bolt, so inspect to see if you are equipped to remove these. If you have the star bolts and do not have the proper tool, you need to get it... attempting to use the wrong tool will not end well.
Use a philips screwdriver to remove the set screw holding the rotor to the hub. You may need an impact screwdriver as these screws seize up with age.
Slide rotor off the hub.

This is for the front: Removal & Installation

1. Remove 2/3 of the brake fluid from the master cylinder.
   
2. Remove or disconnect the following:
   
   • Wheel
     
   • Caliper. Suspend the caliper from the frame with mechanic's wire. Do not allow the caliper to hang from the brake hose.
     
   • Caliper mounting bracket bolts
     
   • Caliper mounting bracket from the steering knuckle assembly
     
   • Brake pads from the caliper mounting bracket
     
   • Clips from the inside ends of the caliper mounting bracket and discard
     

To install:

1. Install or connect the following:
   
   • Clips to the inside ends of the caliper mounting bracket
     
   • Brake pads to the caliper mounting bracket
     
   • Inner pad (1 wear indicator)
     
   • Outer pad (2 wear indicators)
     
   • Caliper mounting bracket to the steering knuckle assembly
     
2. Perform the following procedure before installing the caliper mounting bracket bolts:
   
   • Remove all traces of the original adhesive patch.
     
   • Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.
     
   • Apply red Loctite®272 to the threads of the bolt.
     
3. Install or connect the following:
   
   • Caliper mounting bracket bolts to the steering knuckle. Tighten the caliper guide pin bolts to 74 ft. lbs. (100 Nm) on 15 series or 80 ft. lbs. (108 Nm) on 25/35 series.
     
   • Caliper
     
   • Tire and wheel assembly
     
4. Refill the master cylinder to the proper level with fresh brake fluid. Pump the brake pedal slowly and firmly in order to seat the brake pads. Burnish the brakes as needed.
   

You'll need a T-55 torx bit to remove the rear caliper pins/bolts. You can try using an insert style bit...one that removes from the socket or perhaps purchase a replacement bit (one that would be used in a cordless drill/driver.) The one I used had a 5/16" hex shank. Like you said, there is very little clearance between the head and the leaf springs, which won't allow room for a breaker bar and torx bit. So using a 5/16" wrench, ( I'd recommend a 6 point box wrench to prevent slipping or rounding off.) I was able to loosen the bolt. Or plan B is to remove the caliper mounting bracket which is held on by two 21 or 22 mm hex head bolts. Which would have to be removed to remove the brake rotor.

Tighten the 2 brake caliper mounting bolts to 108 Nm (80 ft. lbs.) . Caliper Mounting Bracket to Knuckle, Front (15 series) 175 Nm (129 ft. lbs.) Caliper Mounting Bracket to Knuckle, Front (25/35 series) 300 Nm (221 ft. lbs.) Brake Caliper Mounting Bolt Rear (15 series) 42 Nm (31 ft. lbs.) Brake Caliper Mounting Bolt Rear (25/35 series) 108 Nm (80 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JC5/JH5) 200 Nm (148 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JH6) 165 Nm (122 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JH7) 300 Nm (221 ft. lbs.) Caliper Mounting Bracket Bolt Rear (NYS) 200 Nm (148 ft. lbs.)
hope this helps

Sometimes they use a T-50 torx bit, and sometimes they use either a 15mm or 18mm bolt, however the caliper bracket is a 21mm bolt