VW Passat & Audi A4 1990-2000

Front Brake Pads

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REMOVAL & INSTALLATION

The front brake calipers used on A4 or Passat models vary depending on the option package installed on the vehicle. The brake caliper type will determine which procedure to use for brake pad removal. One type of brake caliper uses a single hydraulic piston utilizing 2 brake pads. The other type of brake caliper has 2 hydraulic pistons and uses 4 brake pads.

Single Piston Brake Calipers

The inner brake pad type and caliper type may vary slightly from model to model. The Teves/ATE® brake calipers have an inner brake pad that is attached to the brake caliper piston via a built in spring clip on the back of the brake pad and will require caliper removal of 2 sliding pins using a 7mm hex tool to replace. This model also has a spring clip on the outside of the caliper that must be removed before removing the caliper. The Lucas® brake calipers, where the brake pad is not connected to the piston, the caliper can be pivoted upward to replace the inner pad.

  1. Block the rear wheels and apply the parking brake.
  2.  
  3. Loosen the front wheel bolts 1 / 8 turn.
  4.  
  5. Raise and safely support the vehicle. Remove the front wheels.
  6.  
  7. If equipped, disconnect the brake pad wear sensor from the harness.
  8.  
  9. If equipped, remove the cap(s) on the caliper mounting/slide bolt(s).
  10.  
  11. If the inner brake pad is attached to the brake piston (Teves/ATE® caliper), remove both slide-pin/bolts using a 7mm hex tool.
  12.  
    1. If the brake rotor has a significant ridge, using a pair of gooseneck pliers press the inner pad in to push the caliper piston(s) inward until the clearance is sufficient enough for the brake pad to clear the brake rotor.
    2.  
    3. Remove the brake caliper from its mounting bracket, and remove the brake pad installed into the brake caliper piston, then remove the outer brake pad from the mounting bracket. If necessary, support the brake caliper with mechanic's wire once removed from the bracket.
    4.  

  13. If the inner brake pad is not attached to the piston (Lucas®), counter hold the slide pin with a thin open end wrench and remove only the bottom mounting bolt and pivot the caliper upward.
  14.  
    1. With the caliper rotated up, remove the brake pads from the caliper mounting bracket.
    2.  




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Fig. An inner brake pad shown with backing plate retainers used to attach it to the brake caliper piston



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Fig. Use a suitable prytool to remove the tensioning spring and release it from the brake caliper



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Fig. Remove the protective caps to access the caliper mounting fasteners on Teves/ATE® calipers



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Fig. On Teves/ATE® calipers a 7mm hex tool is used to remove the combination, mounting and sliding bolts-1.8L Passat model shown



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Fig. If the brake rotor has a wear ridge on the outer circumference, squeeze between the brake pad backing and the ridge on the caliper to press the caliper piston in allowing clearance between the pad and the ridge



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Fig. Rock the caliper back and forth several times, and then slide it along with the inner brake pad away from the brake rotor



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Fig. A c-clamp centered in the piston's bore can be used to press a front brake caliper piston back, or . . .



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Fig. . . . use a tool designed specifically for the job



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Fig. Apply a light coat of an anti-seize compound to the metal backing of the brake pads where the contact the caliper bracket



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Fig. Apply a light coat of an anti-seize compound to the caliper bracket where is contacts the metal locating tabs of the brake pads



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Fig. Apply a light coat of an anti-seize compound to the raised rectangles on the outer portion of the brake caliper



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Fig. Apply a light coat of an anti-seize compound to the portion of the brake caliper that contacts the back of the outer brake pad. The outline of the caliper contact area is clearly visible



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Fig. Apply a light coating of suitable high-temperature brake caliper grease to the smooth surface of the caliper guide bolt



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Fig. Always clean and lubricate the sliding pin with a an approved high-temperature brake grease



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Fig. If the brake caliper is retained with a hex bolt, counter-hold the sliding pin with a thin open-end wrench



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Fig. A thin open end wrench can either be purchased or fabricated by carefully grinding down a regular wrench

To install:

  1. Clean the brake caliper and all sliding surfaces. Press the caliper piston fully back into the caliper housing. Check for leaking fluid, damaged dust boots and frozen pistons.
  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. Install the outer brake pads in the caliper mount and the inner pad into the brake caliper or onto the caliper bracket as necessary. Lower the caliper over the brake pads.
  6.  
  7. On models with an inverted 7mm hex slide/mounting bolt tighten to:
  8.  
  9. Teves/ATE® caliper slide bolt-to-caliper bracket: 18 ft. lbs. (25 Nm)
  10.  
  11. On Girling® and Lucas® calipers with a hex head mounting bolt using a new bolt tighten to:
  12.  
  13. 1990-97 Passat models (Girling®) caliper mounting bolt-to-slide pin (replace bolt): 25 ft. lbs. (35 Nm)
  14.  
  15. 1998-00 Passat models (Lucas®) caliper mounting bolt-to-slide pin (replace bolt): 22 ft. lbs. (30 Nm)
  16.  
  17. If equipped, check that the pad springs are correctly seated.
  18.  
  19. If equipped, connect the brake pad wear sensor 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.
  20.  
  21. 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 in a crisscross pattern to:
  22.  

Lug bolts:



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


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

  1. Check and top off the brake fluid as necessary.
  2.  
  3. Before test driving, pump the brake pedal slowly and steadily in 2 inch (50mm) increments until the brake pedal has a firm feel.
  4.  

Dual Piston Brake Calipers
  1. Block the rear wheels and apply the parking brake.
  2.  
  3. Loosen the front wheel bolts 1 / 8 turn.
  4.  
  5. Raise and safely support the vehicle. Remove the front wheels.
  6.  
  7. If equipped, disconnect the brake pad wear sensor from the harness.
  8.  
  9. Install one of the removed lug bolts to secure the brake disc.
  10.  
  11. Remove both T-40 Torx® bolts securing the outer brake pads.
  12.  
  13. Push the piston back into the caliper housing by inserting a suitable flat blade screwdriver between the outer brake pad backing plate and the floating caliper frame, and prying the frame outward alternating between the top and bottom brake pad.
  14.  
  15. Release the outer pads from the bracket and remove the pads.
  16.  
  17. Press the caliper bracket inward as far as possible, then carefully press the inner brake pads off the caliper pistons and remove them.
  18.  

To install:

  1. Clean the brake caliper housing making sure to remove any residual adhesive left from the outer brake pads.
  2.  
  3. Install the top and bottom inner brake pads taking care to not damage the protective boots.
  4.  
  5. Move the caliper bracket outward as far as possible.
  6.  
  7. Remove the protective barrier from the back of the outer brake pads and install the pads, then press the brake pedal several times in slow even strokes until the pads seat and the brake pedal pumps up, then install new Torx® bolts and tighten to:
  8.  
  9. Torx® brake pad retaining bolt-to-caliper (replace): 18 ft. lbs. (25 Nm)
  10.  
  11. If equipped, connect the brake pad wear sensor 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. Remove the wheel lug bolt and install the wheel, making sure to not lean the wheel on the brake caliper, otherwise the pads may be dislodged.
  14.  
  15. 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 in a crisscross pattern to:
  16.  
  17. Lug bolts: M14 x 1.5: 89 ft. lbs. (120 Nm)
  18.  


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

  1. Check and top off the brake fluid as necessary.
  2.  
  3. Before test driving, pump the brake pedal slowly and steadily in 2 inch (50mm) increments until the brake pedal has a firm feel.
  4.  

Inspection
  1. Check the pad for thickness. The minimum friction material thickness is:
  2.  
  3. 0.079 inches (2.0mm)
  4.  
  5. Check the condition of the brake friction material. Replace the brake pads if:
  6.  
  7. The friction material is cracking
  8.  
  9. The friction material is contaminated by oil or another fluid
  10.  
  11. The friction material is coming loose from the backing plate
  12.  
  13. Check the pattern of wear of the friction material. If the pads are wearing unevenly or on an angle, there may be a problem with the caliper hanging up on its slides. Clean and lubricate them as necessary.
  14.  
  15. If the inside pad is worn more than the outside pad, the caliper may be seized on the sliding pins. Clean and lubricate the pins and check for free movement of the caliper.
  16.  
  17. If the brake pads from one caliper are worn significantly more than those from the caliper on the opposite side of the vehicle:
  18.  
  19. The caliper with the unworn pads may be completely frozen. Check the piston to see if it retracts smoothly. Check to see if the dust boot is intact.
  20.  
  21. The caliper with the unworn pads may have an internally blocked brake line. Check to see if the piston will retract smoothly and try bleeding the caliper to see if the fluid flow is restricted.
  22.  
  23. The caliper with the excessively worn pads may be binding and not releasing. Check that the piston retracts smoothly and that the dust boot is intact.
  24.  
  25. The caliper with the excessively worn pads may not be releasing. The caliper may have a restricted flexible brake line. Check to see if the piston will retract smoothly and try bleeding the caliper to see if the fluid flow is restricted.
  26.  

If a problem is suspected, repair or replace the component(s) as necessary.

To check for a binding or a caliper that fails to release sufficiently:

  1. Raise and safely support the vehicle.
  2.  
  3. Put the vehicle in neutral with the ignition OFF and the parking brake released.
  4.  
  5. With the help of an assistant, have them apply the foot brake while attempting to rotate a wheel. The wheel should not be able to be rotated.
  6.  
  7. Have the assistant release the foot brake. The wheel should rotate freely, although on the rear wheels some smooth mechanical resistance may be felt as the axle(s) and/or drive shaft(s) rotate. If however, a significant amount of effort is required to rotate the wheel, there is very likely a problem with the brake caliper for that wheel. When testing the rear wheels, make sure the parking brake is properly adjusted and not causing excessive drag.
  8.  



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Fig. To check the brake pad for wear, measure the lining thickness

 
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