1996 VOLKSWAGEN PASSAT brake

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Brake pads, removing and installing

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 parking brake cable from brake caliper
(arrow).
- Remove securing bolts from brake caliper housing; counter-hold on guide pins. - Remove brake pads. Page 7 of 10Rear wheel brakes, servicing (disc brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.5

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Installing

Note:
Before pressing the piston back, remove some
brake fluid from the reservoir. Use a bleeder
bottle or a plastic bottle which is only used for
brake fluid. Brake fluid is poisonous and must not
be siphoned by mouth through a hose. Note: - Thread in piston by turning knurled wheel of
special tool 3272 clockwise.
- Install brake pads. Install special tool 3272 so that the collar (arrow)
of the tool is seated against the brake caliper. If the piston is difficult to move, use a 13 mm
open end wrench on the flats (arrow A) provided
for this purpose. If the piston is pushed back with a piston resetting
tool or by operating the foot brake, the automatic
adjustment in the brake caliper will be destroyed. Page 8 of 10Rear wheel brakes, servicing (disc brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.5

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- Secure brake caliper housing with new self-
locking bolts. Note: - Attach parking brake cable (arrow) to brake caliper housing. 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. Page 9 of 10Rear wheel brakes, servicing (disc brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.5

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Parking brake, adjusting (disc brakes)

Note:
Due to the self-adjusting rear brakes there is no
requirement to adjust the parking brake.
Adjustment is only necessary after replacing
parking brake cables, brake calipers, brake
pads and brake discs. Remove hand grip and central console to allow
access to adjusting nuts (arrows) Page 46-39 . - Parking brake lever in "off" position. Tighten
adjusting nut until lever (arrow) lifts off the brake
caliper stop.
- A gap of max. 1.5 mm from stop (arrow) is
permissible each side but should be set the same
on both sides.
- Pull parking brake on and then release again. - Check that both wheels turn freely. Page 10 of 10Rear wheel brakes, servicing (disc brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.5

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Parking brake lever
assembly overview
1 - Parking brake lever Different versions for
rear drum and disc
brakes Before removing
remove center console 2 - Hand grip Pry trim up with a
small screwdriver then
pull forward to remove
Fig. 2 3 - Adjusting nut Adjusting parking
brake:
- Vehicles with drum
brakes Page 46-26 - Vehicles with disc
brakes Page 46-36 Page 1 of 9Parking brake lever assembly overview12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6

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4 - Lock nut
5 - Compensator
6 - Parking brake lever
trim First pull off parking
brake hand grip then
pull trim forward
Fig. 2 7 - Hex nut
8 - Parking brake cable Different versions for
rear drum and disc
brakes Allocation see Parts
catalog Page 2 of 9Parking brake lever assembly overview12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6

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The parking brake cable is secured by clamps to the
axle beam in the center of the two colored marks
(arrow). Fig. 1 Parking brake cable installation
position Fig. 2 Hand grip, removing - Pry up parking brake cable trim with a screwdriver
and pull grip and trim off forward. Page 3 of 9Parking brake lever assembly overview12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6

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Fig. 3 Center console, removing - Remove rear ashtray (center console). - Remove console rear securing screws (arrows). Page 4 of 9Parking brake lever assembly overview12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6