VW Passat & Audi A4 1990-2000

Cables

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REMOVAL & INSTALLATION
1990-97 Passat Models
  1. Using a suitable flat-blade screwdriver, pry up on the top handbrake trim and pull the grip along with the trim off the lever.
  2.  
  3. Remove the rear ashtray, and then remove the screws securing the rear portion of the console.
  4.  
  5. Counterhold the adjustment nut and lock nut, loosen the lock nut and remove both nuts.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the cables from their routing clamps.
  10.  
  11. Disconnect the cables at the rear brake caliper and remove the cable assemblies.
  12.  
  13. Installation is in reverse order of removal.
  14.  

A4 And 1998-00 Passat Models
  1. Raise and safely support the rear wheels.
  2.  
  3. On Front Wheel Drive models, remove the heat shield above the exhaust in the center tunnel.
  4.  
  5. Locate the threaded adjusters. On All Wheel Drive (AWD) models, they are located in the front of the lower control arms, on Front Wheel Drive (FWD) vehicles, they are located in the tunnel on the underbody of the vehicle.
  6.  
  7. Remove the locking clip between the hex nut and the adjustment housing.
  8.  
  9. Counter hold the hex nut with a 13mm wrench and thread the adjustment housing to loosen the cable until the adjustment housing is fully loosened, then slide the 2 portions of the cable toward one another.
  10.  
  11. Remove the lock clip at the brake caliper and remove the cable, taking care to not damage the cable boot.
  12.  
  13. On Front Wheel Drive models, remove the heat shield above the muffler and push aside.
  14.  
  15. Remove the cables from the cable brackets. Should the assembly aid fall out it is not necessary to reinstall it.
  16.  
  17. Using a suitable flat blade screwdriver, remove the cables from the retaining bracket at the under body tunnel where the cables enter the interior of the vehicle.
  18.  
  19. Remove the rear portion of the center console, then using a suitable flat blade screwdriver, push the cables toward the parking brake lever and press the cable ball end out of the bracket.
  20.  
  21. From under the vehicle, press the guide sleeve-locking element together and pull the cables out of the guide sleeve.
  22.  

To install:

  1. Guide the parking brake cables through until the guide sleeve locks into place.
  2.  
  3. If not previously removed, remove any plastic parts at the hand brake lever adjustment bracket as they are not needed for installation.
  4.  
  5. Using a No. 2 flat-blade screwdriver, lock the adjustment bracket at the hand brake lever to prevent it from turning.
  6.  
  7. Insert the cable end ball through the mounting in the adjustment bracket, making sure the cable locks into place in the bracket.
  8.  
  9. Working under the vehicle, route the cables through their routing brackets and attach them to the brake caliper.
  10.  
  11. The balance of installation is in reverse order of removal noting the following:
  12.  
  13. Adjust the parking brake cable and check its operation.
  14.  

ADJUSTMENT
1990-97 Passat Models
  1. Make sure the brakes are properly bled and the foot brake operation is in normal working order.
  2.  
  3. Using a suitable flat blade screwdriver, pry up on the top handbrake trim and pull the grip along with the trim off the lever.
  4.  
  5. Remove the rear ashtray, and then remove the screws securing the rear portion of the console.
  6.  
  7. Counterhold the adjustment nut and lock nut, loosen the lock nut and remove both nuts.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Turn the adjustment nut for both cables until the arm for each of the brake calipers is just lifted off the stop.
  12.  
  13. Pull up on the parking brake and release.
  14.  
  15. Check the clearance between the arm and the stop. The arm should not be resting on the stop nor should the clearance exceed 1 / 16 inch (1.5mm).
  16.  
  17. If necessary readjust the cable(s). Once properly adjusted, lock the adjustment nut in place with the lock nut.
  18.  
  19. Apply the parking brake and release, making sure both wheels can be moved once released.
  20.  
  21. Carefully lower the vehicle and install the removed interior trim.
  22.  

A4 And 1998-00 Passat Models
  1. Make sure the brakes are properly bled and the foot brake operation is in normal working order.
  2.  
  3. Press the brake pedal down firmly at least one time with the parking brake fully released.
  4.  
  5. Remove the ashtray from the rear, center console.
  6.  
  7. Slide a No. 2 flat blade screwdriver through the hand brake's rear mounting bracket and into the compensating bar to prevent it from turning.
  8.  
  9. Locate the threaded adjusters. On All Wheel Drive (AWD) models it is located in the front of the lower control arms, on Front Wheel Drive (FWD) vehicles, they are located in the tunnel on the underbody of the vehicle.
  10.  
  11. Remove the locking clip between the hex nut and the adjustment housing.
  12.  
  13. Counter hold the hex nut with a 13mm wrench and thread the adjustment housing to loosen the cable until the adjustment housing is fully loosened, then slide the 2 portions of the cable toward one another.
  14.  
  15. Back off the adjusting nut until the slot for the locking clip is visible and install the clip.
  16.  
  17. Pull both cable sleeve adjusters apart evenly, until the cables are tensioned, taking care to not move the lever on the brake caliper.
  18.  
  19. Remove the screwdriver holding the compensator and apply the parking brake firmly and release it at least 3 times.
  20.  
  21. Check the parking brake tension and use the individual tensioners to increase or decrease both of the cable adjustments as necessary.
  22.  
  23. Turn the adjusters for both cables until the arm for each of the brake calipers is just lifted off the stop.
  24.  
  25. Pull up on the parking brake and release.
  26.  
  27. Check the clearance between the arm and the stop. The arm should not be resting on the stop nor should the clearance exceed 1 / 16 inch (1.5mm).
  28.  
  29. If necessary readjust the cable(s).
  30.  
  31. Apply the parking brake and release, making sure both wheels can be moved once released.
  32.  
  33. Carefully lower the vehicle and install the removed interior trim.
  34.  



Click image to see an enlarged view

Fig. When properly adjusted, the caliper's parking brake arm should have a small clearance between the stop and the arm

 
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