Rear Wheel Brakes, Servicing (Disc Brakes)
Rear wheel brakes (disc brakes), servicing
Special tools and equipment
- VAG 1331 Torque wrench or equivalent
- VAG 1332 Torque wrench or equivalent
- VAG 1410 Torque wrench or equivalent
- VAG 1869/2 Brake pedal depressor or equivalent
Note:
^ After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position.
^ To draw off brake fluid from the reservoir, use brake filler and bleeder unit VAS 5234.
^ Install brake pedal depressor VAG 1869/2 before removing a brake caliper or disconnecting a brake hose from the brake caliper.
1. Phillips-head screw, 4 Nm (35 inch lbs.)
2. Brake disc
- Thickness 9 mm (0.354 inch)
- Wear limit 7 mm (0.276 inch)
- When worn, always replace both sides on an axle.
3. Cap
- Pressing off and driving in
4. Self-locking 12-point nut, 175 Nm (129 ft. lbs.)
- Replace each time after removing
5. Wheel hub with wheel bearing and rotor
- Replace each time after removing
- Only replace complete
- Removing and installing
6. Hex bolt, 60 Nm (44 ft. lbs.)
- With dished spring washer
7. Splash plate
8. Stub axle
9. Parking brake cable
- Adjusting parking brake
10. Axle beam
11. ABS speed sensor
- Before inserting sensor, clean mounting hole inner surface and coat with lubricating paste G 000 650
12. Hex socket head bolt 8 Nm (70 inch lbs.)
13. Hex socket head bolt, 65 Nm (48 ft. lbs.)
14. Brake carrier with guide pins and protective cap
- Supplied as replacement part, assembled with sufficient grease on guide pins
- If protective caps or guide pins are damaged use repair kit. Use grease packet supplied to lubricate guide pins.
15. Brake hose/brake line
- With banjo bolt and seals
- Banjo bolt to brake caliper tightening torque 38 Nm (28 ft. lbs.)
- Do not disconnect brake hose when changing brake pads
16. Self-locking hex bolt, 35 Nm (26 ft. lbs.)
- Always replace
17. Brake caliper
- Do not disconnect brake hose when changing brake pads
- Removing:
- Remove brake pad -Item 18.
- Install brake pedal depressor VAG 1869/2
- Remove brake hose -Item 15 from brake caliper
- Installing:
- Install brake pads -Item 18.
- Connect brake hose -Item 15 to brake caliper
- Remove brake pedal depressor VAG 1869/2
- Bleed brake system.
- Servicing
- Parking brake cable must be adjusted first after maintenance or replacement.
- Adjusting parking brake
18. Brake pads
- Thickness
- Wear limit
- Checking thickness:
- Always replace both sides on an axle.
- Removing and installing
19. Pad retaining springs
- Replace always when changing pads
Brake pads, removing and installing
Special tools and equipment
- 3272 Resetting and removal tool
- VAG 1331 Torque wrench or equivalent
Note: Mark brake pads when removing if they are to be reused. Re-install in their original position to prevent uneven braking!
Removing
- Remove wheels.
- Remove clip -1-.
- Press brake lever-2- in direction of arrow and unhook brake cable -3-.
- Take parking brake cable out of brake caliper mounting.
- Remove securing bolts from brake caliper housing, to do this counterhold on guide pins.
- Remove brake caliper housing and secure with wire so that the weight of the brake caliper does not stress or damage the brake hose.
- Remove brake pads and pad retaining springs -arrows-.
- Clean brake caliper housing, in particular the bonding surface for the brake pad. It must be free of adhesive and grease residues.
Use methylated spirit only for cleaning the brake caliper housing.
Installing
Note: Before pressing the piston back, use a bleed bottle to draw off brake fluid from reservoir. Otherwise brake fluid overflow out of the reservoir if brake fluid has been topped off and cause damage.
- Screw in piston by turning knurled wheel of special tool 3272 clockwise, do not damage protective cap when doing this.
- To help screwing in, use special tool 3272/1.
Note:
- Install special tool 3272 so that the collar (arrow) of the tool is seated on connecting piece 3272/1.
- If the piston is difficult to move, use a 13 mm (0.512 inch) AF open end wrench on the flats (arrow -A-) provided for this purpose.
- Insert brake pads and brake pad retaining springs -arrows- into brake carrier.
- Remove protective foil off outer brake pad backplate.
- Secure brake caliper housing with new self-locking bolts.
Note: The repair kit includes four self-locking hex bolts which must be installed in all cases.
- Press brake lever-2- in direction of arrow and attach parking brake cable.
- Install clip -1-.
- Adjusting parking brake.
- Install wheels.
Note:
- After each brake pad change, firmly depress brake pedal several times with vehicle stationary, so that the brake pads are properly seated in their normal operating position.
- After changing brake pads check brake fluid level.