Volkswagen Cars 2000-05

Brake Pads

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Adjustment




NOTE
Parking brake adjustment is only necessary after replacing brake pads or other brake components. If the parking brake does not hold the vehicle, the rear calipers and brake pads must be removed for inspection.

  1. Raise and safely support the rear of the vehicle on jackstands and remove the rear wheels.
  2.  
  3. With the parking brake handle down and the brake fully released, firmly apply the brake pedal once.
  4.  
  5. Pull the parking brake lever up 2-3 clicks. If the rear wheels cannot be turned by hand, no adjustment is required.
  6.  
  7. If adjustment is required, loosen the locknuts and the adjusting nuts to just relieve the tension on the cables.
  8.  
  9. Hold the release button on the handle and move the handle up and down 3 or more times to seat the cables and make sure they move freely, then leave the handle down.
  10.  
  11. Tighten the cable adjusting nuts evenly until the actuating levers on the calipers just move off their stops. The gap must be less than 0.059 inch (1.5mm).
  12.  
  13. To check for correct adjustment:
    1. At the first click, the rotors should turn by hand with some drag.
    2.  
    3. At the second click, the rotors should be difficult to turn.
    4.  
    5. At the third click, it should not be possible to turn the rotors by hand.
    6.  
    7. When the brake handle is released, the rotors should turn freely.
    8.  

  14.  

Inspection





The brake pad wear limit is 0.080 inch (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.
 
Check the rotor for signs of heat cracks or discoloration.
 
Minimum allowed thickness of solid brake rotors is 0.393 inches (10mm). Maximum allowed run-out is 0.002 inch (0.06mm).
 

Inspection of the rear brake pads is similar to the inspection of the front brake pads. Please refer to the front brake pad inspection procedures.

Removal & Installation





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Fig. Once the caliper is supported, slide the pads out of the rotor



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Fig. Lube the guide bolts with a synthetic caliper grease



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Fig. Always inspect the anti rattle clips for damage

Some brake pads contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  1. Raise and safely support the vehicle and remove the rear wheels.
  2.  
  3. Remove a sufficient quantity of brake fluid from the master cylinder reservoir to prevent it from over flowing when installing the pads. This is necessary as the caliper piston must be forced into the cylinder bore to provide sufficient clearance to install new pads.
  4.  
  5. Remove the parking brake cable clip from the caliper. Disconnect the parking brake cable.
  6.  
  7. Hold the guide pin with a back-up wrench and remove the upper mounting bolt from the brake caliper.
  8.  
  9. Swing the caliper downward and remove the brake pads.
  10.  
  11. Check the rotor for scoring and resurface or replace as necessary. Check the caliper for fluid leaks or a damaged dust seal. If any damage is found, the caliper will require overhauling or replacement.
  12.  

To install:

  1. Retract the piston into the housing by rotating the piston clockwise.
  2.  
  3. Carefully clean the anchor plate and install the new brake pads onto the pad carrier.
  4.  
  5. Install the caliper to the pad carrier using a new self locking bolt or a thread locking compound and tighten to 26 ft. lbs. (35 Nm).
  6.  
  7. Attach the hand brake cable to the caliper. It may be necessary to back off the adjustment nuts at the hand brake handle.
  8.  
  9. Fill the reservoir with brake fluid and pump the brake pedal about 40 times with the engine off to set the piston. Setting the piston with the power assist could cause the piston to jam.
  10.  
  11. Check the parking brake operation, adjust the cable if necessary.
  12.  
  13. Road test the vehicle.
  14.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the rear wheels.
  4.  
  5. Remove the parking brake cable clip from the caliper. Disconnect the parking brake cable.
  6.  
  7. Hold the guide pin with a back-up wrench and remove the upper mounting bolt from the brake caliper.
  8.  
  9. Swing the caliper downward and remove the brake pads.
  10.  

To install:

  1. Retract the piston into the housing by rotating the piston clockwise.
  2.  
  3. Install the new brake pads onto the pad carrier.
  4.  
  5. Install the caliper to the pad carrier using a new self locking bolt or a thread locking compound and torque to 26 ft. lbs. (35 Nm).
  6.  
  7. Attach the hand brake cable to the caliper.
  8.  
  9. Check the parking brake operation and adjust the cable if necessary.
  10.  
  11. Install the wheels.
  12.  

  1. Raise and support the vehicle. Remove the rear wheels.
  2.  
  3. If equipped, disconnect the brake pad wear sensor from the harness.
  4.  
  5. Counterhold the lower sliding pin using a thin open-end wrench and remove the caliper-to-sliding pin hex bolt.
  6.  
  7. Pivot the caliper upward or if necessary remove the upper caliper-to-sliding pin hex bolt.
  8.  
  9. Using a brake caliper retraction tool, select the appropriate sized piston press arbor and install the tool onto the brake caliper. Following the tool manufacturer's recommendations, use the tool to rotate the caliper piston clockwise as it is pressed into the brake caliper housing, until it is fully retracted.
  10.  



Click image to see an enlarged view

Fig. Use a thin open-end wrench to . . .



Click image to see an enlarged view

Fig. . . . support the caliper sliding pin when removing the caliper mounting bolt



Click image to see an enlarged view

Fig. Use a disc brake caliper piston retracting tool that will rotate the caliper piston as it is pressed into the caliper



Click image to see an enlarged view

Fig. The rear caliper piston is slotted to allow a retracting tool to rotate the piston when replacing the brake pads

To install:

  1. Clean the brake caliper and all sliding surfaces. With the caliper piston pressed fully back into the caliper housing, check for leaking fluid and damaged dust boots.
  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. Lubricate the slider bolts with approved brake grease.
  6.  
  7. Install the brake pads onto the bracket assembly, and then carefully lower the caliper over the caliper mount. Check and make sure that the pad springs are correctly seated.
  8.  
  9. Replace all removed caliper-to-sliding pin bolts and torque to:
  10.  


    1990-97 Passat models: 25 ft. lbs. (35 Nm)
     
    1998-00 Passat models: 22 ft. lbs. (30 Nm)
     

  11. 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.
  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 to specification in a crisscross pattern to:
  14.  


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



CAUTION
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 Section.
  2.  
  3. Remove the rear wheels.
  4.  
  5. Remove the parking brake cable clip from the caliper. Disconnect the parking brake cable.
  6.  
  7. Hold the guide pin with a back-up wrench and remove the upper mounting bolt from the brake caliper.
  8.  
  9. Swing the caliper downward and remove the brake pads.
  10.  

To install:

  1. Retract the piston into the housing by rotating the piston clockwise.
  2.  
  3. Install the new brake pads onto the pad carrier.
  4.  
  5. Install the caliper to the pad carrier using a new self locking bolt or a thread locking compound and torque to 271 inch lbs. (35 Nm).
  6.  
  7. Attach the hand brake cable to the caliper.
  8.  
  9. Check the parking brake operation and adjust the cable if necessary.
  10.  
  11. Install the wheels.
  12.  

 
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