Audi Cars 1999-05

Brake Pads

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Inspection



Inspection of the rear brake pads is similar to the inspection of the front brake pads. Please refer to the front brake pad inspection procedures.

Removal & Installation



  1. Raise and support the vehicle. Remove the rear wheels.
  2.  
  3. If equipped, disconnect the brake pad wear sensor from the harness.
  4.  
  5. Counterhold the lower sliding pin using a thin open-end wrench and remove the caliper-to-sliding pin hex bolt.
  6.  
  7. Pivot the caliper upward or if necessary remove the upper caliper-to-sliding pin hex bolt.
  8.  
  9. Using a brake caliper retraction tool, select the appropriate sized piston press arbor and install the tool onto the brake caliper. Following the tool manufacturer's recommendations, use the tool to rotate the caliper piston clockwise as it is pressed into the brake caliper housing, until it is fully retracted.
  10.  



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Fig. Use a thin open-end wrench to . . .



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Fig. . . . support the caliper sliding pin when removing the caliper mounting bolt



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Fig. Use a disc brake caliper piston retracting tool that will rotate the caliper piston as it is pressed into the caliper



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Fig. The rear caliper piston is slotted to allow a retracting tool to rotate the piston when replacing the brake pads

To install:

  1. Clean the brake caliper and all sliding surfaces. With the caliper piston pressed fully back into the caliper housing, check for leaking fluid and damaged dust boots.
  2.  
  3. If equipped, install a new brake pad wear sensor in the pad if the plastic part has been worn through on the old sensor. New sensors are not required unless the wire inside the plastic part has been exposed.
  4.  
  5. Lubricate the slider bolts with approved brake grease.
  6.  
  7. Install the brake pads onto the bracket assembly, and then carefully lower the caliper over the caliper mount. Check and make sure that the pad springs are correctly seated.
  8.  
  9. Replace all removed caliper-to-sliding pin bolts and torque to:
  10.  


    1990-97 Passat models: 25 ft. lbs. (35 Nm)
     
    1998-00 Passat models: 22 ft. lbs. (30 Nm)
     

  11. If equipped, connect the brake wear sensor wire to the harness. Check for a good connection as most problems with the sensor circuit are caused by faulty connections. Check that the wire is held by the loop in the dust cover and the connector is held at the clips.
  12.  
  13. Install the wheels and hand tighten the lug bolts. Lower the vehicle carefully until the tires begin to contact the surface and torque the lug bolts to specification in a crisscross pattern to:
  14.  


    M12 x 1.5 lug bolts: 81 ft. lbs. (110 Nm)
     
    M14 x 1.5 lug bolts: 89 ft. lbs. (120 Nm)
     



CAUTION
Failure to properly torque the wheels to the correct torque using the proper sequence could cause a brake pulsation and rotor warpage.

  1. Before test driving, pump the brake pedal slowly and steadily in 2 inch (50mm) increments until the brake pedal has a firm feel.
  2.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the rear wheels.
  4.  
  5. Remove the parking brake cable clip from the caliper. Disconnect the parking brake cable.
  6.  
  7. Hold the guide pin with a back-up wrench and remove the upper mounting bolt from the brake caliper.
  8.  
  9. Swing the caliper downward and remove the brake pads.
  10.  

To install:

  1. Retract the piston into the housing by rotating the piston clockwise.
  2.  
  3. Install the new brake pads onto the pad carrier.
  4.  
  5. Install the caliper to the pad carrier using a new self locking bolt or a thread locking compound and torque to 26 ft. lbs. (35 Nm).
  6.  
  7. Attach the hand brake cable to the caliper.
  8.  
  9. Check the parking brake operation and adjust the cable if necessary.
  10.  
  11. Install the wheels.
  12.  

 
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