Volkswagen Cars 2000-05

Cables

Print

Adjustment



  1. Remove center console extension, Body Interior - Repair Group 68
  2.  
  3. Firmly depress brake pedal once.
  4.  
  5. The parking brake lever must be in the "rest/off" position. Tighten the adjusting nut until the lever lifts off the brake caliper stop. A gap of max. 1.5 mm from stop is allowed on each side.

    Click image to see an enlarged view

    Fig. The parking brake lever must be in the "rest/off" position. Tighten adjusting nut until lever (arrow) lifts off the brake caliper stop. A gap of 1.5mm max. from the stop (arrow) is allowed on each side-FWD models

  6.  
  7. Pull on parking brake three times and then release again.
  8.  
  9. Check that both wheels turn freely. Adjust the adjustment nut if necessary.
  10.  
  11. Lock adjustment nut in position with the lock nut.
    NOTE
    Due to the automatic rear wheel brake adjustment there is no requirement to adjust the parking brake after making new/initial adjustment.

  12.  


NOTE
Anytime you replace the parking brake cables, brake calipers or brake discs (rotors) you must perform the following adjustment.

  1. Depress brake pedal firmly at least one time.
  2.  
  3. Make sure the parking brake lever in the fully released position.
  4.  
  5. Remove rear ashtray from the center console.
  6.  
  7. Remove any plastic components that are installed on the compensator. They do not need to be installed again.
  8.  
  9. Secure the compensator with a screwdriver to keep it from turning.
    NOTE
    On Front Wheel Drive (FWD) models, the adjustment for the parking brake cables is located on the underside of the vehicle in the tunnel. On All Wheel Drive (AWD) models, the adjustment is located in front of the lower control arm.



    Click image to see an enlarged view

    Fig. Secure the compensator with a screwdriver to keep it from turning (shown without center console for illustrative purposes)

  10.  
  11. Remove the locking element .
  12.  
  13. Turn the adjusting nut to its stop, so that groove in locking element is covered.
  14.  
  15. Push the cable sleeves together at the same time.
  16.  
  17. Back out the adjusting nut until the groove in locking element is visible.
  18.  
  19. Insert the locking element.
  20.  
  21. Pull the cable sleeves apart at the same time until the cables are tightened. The lever on the brake caliper must not be lifted off.

    Click image to see an enlarged view

    Fig. View of the adjusting nut (1), cable sleeves (2 and 3) and locking element (4)

  22.  
  23. Remove the screwdriver from compensator, then apply the parking brake 3 times.
    NOTE
    After a successful parking brake adjustment, the colored O-ring must not be visible. This ensures that the mechanism of the parking brake cable adjustment elements are adequately protected from dirt and/or water spray.

  24.  
  25. Check tension of parking brake cables and, if necessary, turn the adjusting nut in or out accordingly.

    Click image to see an enlarged view

    Fig. After successfully adjusting the parking brake, the colored O-ring (1) must not be visible. Check the tension of the parking brake cables and, if necessary, turn the adjusting nut (A) in or out accordingly

  26.  
  27. Turn adjusting nut out or in so far, until the dimension shown in the illustration on the brake caliper is adjusted to 1.5 mm.
    NOTE
    Due to the automatic rear brake adjuster, there is no need to adjust the parking brake after making initial adjustment.



    Click image to see an enlarged view

    Fig. Turn adjusting nut out or in so far, until the dimension (A) on the brake caliper is adjusted to 1.5 mm

  28.  

Rear Disc Brakes

NOTE
A new adjustment is only necessary after replacing, parking brake cables, brake calipers and brake discs.

  1. Remove center console extension.
  2.  
  3. Firmly depress brake pedal three times.
  4.  
  5. Pull parking brake three times and then release again.
  6.  
  7. The parking brake lever must be in the "rest/off" position. Tighten adjusting nut until lever (arrow) lifts off the brake caliper stop. A gap of 0.039-0.118 in. (1.0-3.0mm) from the stop (arrow) is allowed on each side.

    Click image to see an enlarged view

    Fig. The parking brake lever must be in the "rest/off" position. Tighten adjusting nut until lever (arrow) lifts off the brake caliper stop. A gap of 0.039-0.118 in. from the stop (arrow) is allowed on each side-FWD models



    Click image to see an enlarged view

    Fig. The parking brake lever must be in the "rest/off" position. Tighten adjusting nut until lever (arrow) lifts off the brake caliper stop. A gap of 0.039-0.118 in. from the stop (arrow) is allowed on each side-AWD models

  8.  
  9. Check that both wheels turn freely. Adjust the adjustment nut if necessary.
    NOTE
    Due to the automatic rear wheel brake adjustment there is no requirement to adjust the parking brake after making new/initial adjustment.

  10.  

Removal & Installation



  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.  

Disc Brakes
  1. Raise and safely support the vehicle.
  2.  
  3. Release the parking brake. It may be necessary to unscrew the adjusting nuts to provide slack in the brake cable.
  4.  
  5. At each rear wheel brake caliper, remove the spring clip retaining the parking brake cable to the caliper.
  6.  
  7. Lift the cable from the caliper mount and disengage it from the parking brake lever.
  8.  
  9. Pull the cables out from under the vehicle.
  10.  
  11. Installation is the reverse of removal.
  12.  
  13. Adjust the parking brake as described at the beginning of this section.
  14.  

Drum Brakes
  1. Block the front wheels and release the hand brake.
  2.  
  3. Raise and safely support the rear of the vehicle.
  4.  
  5. Remove the rear brake shoes.
  6.  
  7. Remove the brake cable assembly from the back plates.
  8.  
  9. Remove the cable adjusting nuts at the handle and detach the cable guides from the floor pan.
  10.  
  11. Pull the cables out from under the vehicle.
  12.  
  13. Installation is the reverse of removal. Adjust the parking brake and road test the vehicle.
  14.  

 
label.common.footer.alt.autozoneLogo