Volkswagen Cars 2000-05

Brake Caliper

Print

Overhaul




WARNING
If the vehicle is equipped with the Electronic Stability Program (ESP), the ESP pump must be actuated during the bleeding procedure using a proper scan tool, such as VAG 1551, VAG 1552, or equivalent, capable of activating the ESP pump.

The rear brake caliper design is similar to the front brake caliper except that the caliper piston must be withdrawn by turning it counter clockwise using suitable brake caliper retraction/extraction tool. For additional overhaul information, please refer to the front brake caliper overhaul procedures in this section.

To disassemble and overhaul the brake caliper proceed as follows:

  1. Remove the brake caliper assembly.
  2.  
  3. Remove the brake caliper piston by turning it counterclockwise using a commercially available brake caliper retraction/extraction tool.
  4.  
  5. Remove the hydraulic seal from the caliper housing using a plastic wedge, making sure to not damage or scratch the bore of the caliper during removal.
  6.  

To install:

  1. Clean the caliper body and piston with clean rubbing alcohol or brake cleaner. Do NOT allow the solvents to come in contact with any rubber parts.
  2.  
  3. Apply a thin coating of a brake grease lubricant, such as Part No. G 052 150 A2, or equivalent, to the caliper piston-to-brake caliper surface area and the seals.
  4.  
  5. Install the new inner seal into the caliper body bore's seal area.
  6.  
  7. Install the new outer seal onto the outer groove of the caliper piston.
  8.  
  9. Insert the piston into the caliper squarely and turn the piston clockwise using a commercially available brake caliper retraction tool to move the piston into the caliper. The piston should not require excessive force to install.
  10.  
  11. Install the outer protective seal onto the caliper body.
  12.  
  13. Install the brake caliper and bleed the brakes using fresh approved brake fluid.
  14.  
  15. Before test driving, pump the brake pedal slowly and steadily in 2 inch (50mm) increments until the brake pedal has a firm feel.
  16.  

Removal & Installation





Click image to see an enlarged view

Fig. Use two wrenches, one to hold the caliper guide bolt sleeve from spinning and the other to remove the guide bolt itself



Click image to see an enlarged view

Fig. Use a length of wire to hang the caliper. Never let the caliper hang from the brake hose

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. If equipped with ABS, make sure the ignition switch stays OFF and pump the brake pedal 25-35 times to relieve the system pressure.
  2.  
  3. Raise and safely support the vehicle on jackstands and remove the wheels.
  4.  
  5. Disconnect the parking brake cable.
  6.  
  7. Loosen the hydraulic line.
  8.  
  9. Use a back-up wrench to hold the guide pins and remove the caliper bolts.
  10.  
  11. Lift the caliper off the carrier and unscrew it from the hydraulic line.
  12.  
  13. The installation is the reverse of removal.
  14.  


NOTE
Use new caliper mount bolts or clean the old bolts and apply a thread locking compound. Tighten the bolts to 26 ft. lbs. (35 Nm).

  1. Bleed the brakes.
  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. If equipped with ABS, make sure the ignition switch staysOFF
  4.  
  5. Remove the wheels.
  6.  
  7. Disconnect the parking brake cable.
  8.  
  9. Loosen the hydraulic line.
  10.  
  11. Use a back-up wrench to hold the guide pins and remove the caliper bolts.
  12.  
  13. Lift the caliper off the carrier and unscrew it from the hydraulic line.
  14.  

To install:

  1. Thread the caliper onto the hydraulic line and hand-tighten it. Fit the caliper into place on the carrier. Torque the bolts to 26 ft. lbs. (35 Nm).
  2.  
  3. Bleed the brakes.
  4.  
  5. Install the wheels.
  6.  


    Click image to see an enlarged view

    Fig. Rear disc brakes-Passat



    Click image to see an enlarged view

    Fig. Rear disc brakes-Golf, GTI, Jetta and New Beetle



WARNING
If the vehicle is equipped with the Electronic Stability Program (ESP), the ESP pump must be actuated during the bleeding procedure using the VAG 1551, VAG 1552 or an equivalent Data Scan Tool (DST) capable of activating the ESP pump.

  1. Place the gear selector in first gear or Park. Block the rear wheels and apply the parking brake.
  2.  
  3. Loosen the rear wheel bolts 1 / 8 turn.
  4.  
  5. Release the parking brake.
  6.  
  7. Raise and support the vehicle. Remove the rear wheels.
  8.  
  9. If equipped, disconnect the brake pad wear sensor from the harness.
  10.  


NOTE
Do NOT loosen or disconnect the brake caliper fluid hose if the caliper is being removed to access or replace another component. Loosen and disconnect the fluid hose only if the caliper is to be replaced, completely removed or overhauled. If the fluid hose is to remain attached to the caliper, support the caliper assembly with mechanic's wire to avoid damaging the line.

  1. If the caliper is to be completely removed from the vehicle (replaced, disassembled or overhauled):
  2.  
    1. Siphon the brake fluid from the reservoir and fix the brake pedal in the depressed position. Or, remove the reservoir cap and place a thin sandwich bag over the opening, then reinstall the cap without the fluid level float to captivate the system. This will prevent brake fluid from draining out of the brake lines while the line is disconnected from the caliper.
    2.  
    3. Using a flare nut wrench, loosen, but Do NOT disconnect the flexible line to the caliper.
    4.  

  3. Counterhold the brake caliper slide pin and remove the caliper-to-slide pin bolts.
  4.  
  5. If the brake fluid line is to be removed from the caliper, place a suitable drain pan under the caliper, disconnect and plug the fluid line and the caliper. Note, to avoid damage to the flexible brake line, hold the brake line with a flare nut wrench and spin the brake caliper. If the brake line is sealed to the caliper with a crush washer, replace the crush washer with the appropriate replacement part.
  6.  
  7. If the brake caliper mounting bracket is to be removed, remove the caliper bracket-to-knuckle mounting bolts and lift off the bracket. These mounting bolts typically require a sturdy 6-point socket.
  8.  


NOTE
The brake caliper bracket-to-trailing arm bolts may require a significant amount of effort to loosen. Use a proper fitting 6-point 1 / 2 inch drive metric impact socket and sturdy breaker bar to loosen the mounting bolts.

To install:

  1. If the brake fluid line was disconnected, connect the brake line to the caliper and torque to:
  2.  


    Compression fitting: 11 ft. lbs. (15 Nm)
     
    Banjo bolt (replace crush washers): 22 ft. lbs. (30 Nm)
     

  3. To avoid damage to the flexible brake line, hold the brake line with a flare nut wrench and spin the brake caliper. If the brake line is sealed to the caliper with a crush washer, replace the crush washer with the appropriate replacement part.
  4.  
  5. If the caliper bracket was removed
  6.  
    1. Support the caliper temporarily, with mechanic's wire, taking care to not damage the flexible brake hose.
    2.  
    3. Install the bracket on the trailing arm and torque the bolts to:
    4.  


      1990-97 Passat models: 48 ft. lbs. (65 Nm)
       
      1998-00 Passat models: 70 ft. lbs. (95 Nm)
       
      A4 models: 70 ft. lbs. (95 Nm)
       

    5. Install the brake pads in the caliper bracket as outlined in this section.
    6.  

  7. Lubricate the slider bolts with approved brake grease.
  8.  
  9. Lower the brake caliper over the brake pads.
  10.  
  11. Install the caliper-to-slider bolts and torque to:
  12.  


    1990-97 Passat models: 26 ft. lbs. (35 Nm)
     
    1998-00 Passat models: 22 ft. lbs. (30 Nm)
     
    A4 models: models: 26 ft. lbs. (35 Nm)
     

  13. 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.
  14.  
  15. If the brake fluid line was disconnected, bleed the brake system as outlined in this section.
  16.  
  17. 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:
  18.  


    M12 x 1.5 lug bolts: 81 ft. lbs. (110 Nm)
     
    M14 x 1.5 lug bolts: 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. 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 in the beginning of this section.
  2.  
  3. If equipped with ABS, make sure the ignition switch stays OFF and pump the brake pedal 25-35 times to relieve the system pressure.
  4.  
  5. Remove the wheels.
  6.  
  7. Disconnect the parking brake cable.
  8.  
  9. Loosen the hydraulic line.
  10.  
  11. Use a back-up wrench to hold the guide pins and remove the caliper bolts.
  12.  
  13. Lift the caliper off the carrier and unscrew it from the hydraulic line.
  14.  

To install:

  1. Thread the caliper onto the hydraulic line and hand-tighten it. Fit the caliper into place on the carrier. Torque the bolts to 26 ft. lbs. (35 Nm).
  2.  
  3. Bleed the brakes.
  4.  
  5. Install the wheels.

    Click image to see an enlarged view

    Fig. Rear disc brakes-Passat shown



    Click image to see an enlarged view

    Fig. Rear disc brakes-New Beetle

  6.  


CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. If equipped with ABS, make sure the ignition switch stays OFF and pump the brake pedal 25-35 times to relieve the system pressure.
  4.  
  5. Remove the wheels.
  6.  
  7. Disconnect the parking brake cable.
  8.  
  9. Loosen the hydraulic line.
  10.  
  11. Use a back-up wrench to hold the guide pins and remove the caliper bolts.
  12.  
  13. Lift the caliper off the carrier and unscrew it from the hydraulic line.

    Click image to see an enlarged view

    Fig. Rear disc brakes-Passat



    Click image to see an enlarged view

    Fig. Rear disc brakes-Golf, GTI, Jetta and New Beetle

  14.  

To install:

  1. Thread the caliper onto the hydraulic line and hand-tighten it. Fit the caliper into place on the carrier. Torque the bolts to 271 inch lbs. (35 Nm).
  2.  
  3. Bleed the brakes.
  4.  
  5. Install the wheels.
  6.  

 
label.common.footer.alt.autozoneLogo