Volkswagen Cars 2000-05

Brake Pads

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Inspection



The brake pad wear limit is 0.080 inches (2mm). If the pads show signs of heat cracks or if they are worn unevenly, check the caliper for a sticking piston or guides. Check the caliper for signs of fluid leakage or damage to the dust seal. Also check the rotor for signs of heat cracks or discoloration. The minimum allowed thickness of solid brake rotors is 0.393 inches (10mm). Maximum allowed run-out is 0.002 inches (0.06mm). The minimum allowed thickness of vented brake rotors is 0.708 inches (18mm). Maximum allowed run-out is 0.002 inches (0.06mm).

  1. Check the pad for thickness. The minimum friction material thickness is:
  2.  


    0.079 inches (2.0mm)
     

  3. Check the condition of the brake friction material. Replace the brake pads if:
  4.  


    The friction material is cracking
     
    The friction material is contaminated by oil or another fluid
     
    The friction material is coming loose from the backing plate
     

  5. 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.
  6.  
  7. 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.
  8.  
  9. If the brake pads from one caliper are worn significantly more than those from the caliper on the opposite side of the vehicle:
  10.  


    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.
     
    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.
     
    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.
     
    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.
     


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.  



Click image to see an enlarged view

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

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.

Caliper With Guide Pins

The ABS hydraulic modulator is capable of self-pressurizing and can generate pressures above 3000 psi. any time the ignition switch is turned ON. Relieve the system pressure before testing or repairing the hydraulic system. Improper repair or test procedures can cause serious or fatal injury.

  1. Raise and safely support the vehicle on jackstands and remove the front wheels.
  2.  
  3. If the brake fluid reservoir level is near the maximum line, siphon some brake fluid from the reservoir to prevent overflowing when the piston is retracted into the cylinder bore.
  4.  
  5. Hold the lower guide pin with an open wrench and remove the bolt securing the caliper to the guide pin. Do not remove the top bolt.
  6.  
  7. Pivot the caliper up on the upper guide pin and slide the pads straight out to remove them.
  8.  

To install:

  1. Place the old pad against the piston and use a C-clamp to push the piston all the way into the bore. If the rubber boot is split, if there is fluid leaking from the caliper or if the piston will not move in the bore, the caliper must be rebuilt or replaced.
  2.  
  3. Fit the new pads into the carrier and pivot the caliper into place.
  4.  
  5. The original bolts are micro-encapsulated with a thread locking compound. Install a new bolt or clean the old bolt and apply a thread locking compound.
  6.  
  7. When tightening the bolt, be sure to use a back-up wrench to hold the guide pin. Tighten the bolt to 26 ft. lbs. (35 Nm).
  8.  
  9. Pump the brake pedal several times until the pedal is firm, then add new brake fluid as required.
  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the front wheels.
  4.  
  5. Hold the lower guide pin with an open wrench and remove the bolt securing the caliper to the guide pin.
  6.  
  7. Pivot the caliper up on the upper guide pin and slide the pads straight out to remove them.
  8.  

To install:

  1. Compress the caliper piston into the bore.
  2.  
  3. Fit the new pads into the carrier and pivot the caliper into place.
  4.  
  5. The original bolts are micro-encapsulated with a thread locking compound. Install a new bolt or clean the old bolt and apply a thread-locking compound.
  6.  
  7. When tightening the bolt, be sure to use a back-up wrench to hold the guide pin. Torque the bolt to 26 ft. lbs. (35 Nm).
  8.  
  9. Install the wheels.
  10.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the front wheels.
  4.  
  5. Hold the lower guide pin with an open wrench and remove the bolt securing the caliper to the guide pin.
  6.  
  7. Pivot the caliper up on the upper guide pin and slide the pads straight out to remove them.
  8.  

To install:

  1. Compress the caliper piston into the bore.
  2.  
  3. Fit the new pads into the carrier and pivot the caliper into place.
  4.  
  5. The original bolts are micro-encapsulated with a thread locking compound. Install a new bolt or clean the old bolt and apply a thread-locking compound.
  6.  
  7. When tightening the bolt, be sure to use a back-up wrench to hold the guide pin. Torque the bolt to 26 ft. lbs. (35 Nm).
  8.  
  9. Install the wheels.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the front wheels.
  4.  
  5. Hold the lower guide pin with an open wrench and remove the bolt securing the caliper to the guide pin.
  6.  
  7. Pivot the caliper up on the upper guide pin and slide the pads straight out to remove them.
  8.  

To install:

  1. Compress the caliper piston into the bore.
  2.  
  3. Fit the new pads into the carrier and pivot the caliper into place.
  4.  
  5. The original bolts are micro-encapsulated with a thread locking compound. Install a new bolt or clean the old bolt and apply a thread-locking compound.
  6.  
  7. When tightening the bolt, be sure to use a back-up wrench to hold the guide pin. Torque the bolt to 271 inch lbs. (35 Nm).
  8.  
  9. Install the wheels.
  10.  

Caliper With Sleeves And Bushings


Click image to see an enlarged view

Fig. Loosen the caliper mounting bolts



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Fig. Use caution around the brake hoses. Do not nick, crimp, or twist the exterior rubber case of the hose



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Fig. Note the position of each bolt removed



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Fig. Pivot the caliper up and then pull it out to remove



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Fig. Slide the pads out of the caliper



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Fig. Always reinstall a shim. This thin piece of metal is essential to quiet brake operation

  1. Raise and safely support the vehicle on jackstands and remove the front wheels.
  2.  
  3. If the brake fluid reservoir level is near the maximum line, siphon some brake fluid from the reservoir to prevent overflowing when the piston is pushed into the cylinder bore.
  4.  
  5. Put a large C-clamp around the caliper so it contacts the caliper body and the outer brake pad. Tighten the clamp to push the piston into the bore. Remove the clamp and push the caliper in and out to make sure the sleeves and bushings move freely.
  6.  
  7. With a 6mm Allen® socket, remove the 2 bolts holding the caliper to the carrier. Push the caliper up and pivot the bottom of the caliper out of the carrier.
  8.  
  9. Hang the caliper from the front spring with a piece of wire. DO NOT let the caliper hang by the hydraulic line.
  10.  
  11. Remove the anti-rattle springs and the pads from the carrier and note their location.
  12.  

To install:

  1. Fit the anti-rattle springs into place and slide the new pads onto the carrier. The tang should be towards the inner pad.
  2.  
  3. Fit the caliper into place at the top and push up so it can be pivoted into place at the bottom. The tabs on the anti-rattle springs should be pushing against the inside of the caliper.
  4.  
  5. Make sure the caliper mounting bolts are clean. Install the bolts and tighten them to 18 ft. lbs. (25 Nm).
  6.  
  7. Pump the brake pedal several times until the pedal is firm, then add new brake fluid as required.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the 2 bolts holding the caliper to the carrier. Push the caliper up and pivot the bottom of the caliper out of the carrier.
  6.  
  7. Remove the anti-rattle springs and the pads from the carrier and note their location.
  8.  

To install:

  1. Fit the anti-rattle springs into place and slide the new pads onto the carrier.
  2.  
  3. Fit the caliper into place at the top and push up so it can be pivoted into place at the bottom. The tabs on the anti-rattle springs should be pushing against the inside of the caliper.
  4.  
  5. Make sure the caliper mounting bolts are clean. Install the bolts and torque them to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the wheels.
  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the 2 bolts holding the caliper to the carrier. Push the caliper up and pivot the bottom of the caliper out of the carrier.
  6.  
  7. Remove the anti-rattle springs and the pads from the carrier and note their location.
  8.  

To install:

  1. Fit the anti-rattle springs into place and slide the new pads onto the carrier.
  2.  
  3. Fit the caliper into place at the top and push up so it can be pivoted into place at the bottom. The tabs on the anti-rattle springs should be pushing against the inside of the caliper.
  4.  
  5. Make sure the caliper mounting bolts are clean. Install the bolts and torque them to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the wheels.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the 2 bolts holding the caliper to the carrier. Push the caliper up and pivot the bottom of the caliper out of the carrier.
  6.  
  7. Remove the anti-rattle springs and the pads from the carrier and note their location.
  8.  

To install:

  1. Fit the anti-rattle springs into place and slide the new pads onto the carrier.
  2.  
  3. Fit the caliper into place at the top and push up so it can be pivoted into place at the bottom. The tabs on the anti-rattle springs should be pushing against the inside of the caliper.
  4.  
  5. Make sure the caliper mounting bolts are clean. Install the bolts and torque them to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the wheels.
  8.  

Dual Piston Caliper
  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.  


    Torx® brake pad retaining bolt-to-caliper (replace): 18 ft. lbs. (25 Nm)
     

  9. 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.
  10.  
  11. 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.
  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 in a crisscross pattern to:
  14.  


    Lug bolts: 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.  

Single Piston Caliper

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.  




Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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.  


    Teves/ATE® caliper slide bolt-to-caliper bracket: 18 ft. lbs. (25 Nm)
     

  9. On Girling® and Lucas® calipers with a hex head mounting bolt using a new bolt tighten to:
  10.  


    1990-97 Passat models (Girling®) caliper mounting bolt-to-slide pin (replace bolt): 25 ft. lbs. (35 Nm)
     
    1998-00 Passat models (Lucas®) caliper mounting bolt-to-slide pin (replace bolt): 22 ft. lbs. (30 Nm)
     

  11. If equipped, check that the pad springs are correctly seated.
  12.  
  13. 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.
  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.  

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.  

 
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