1996 VOLKSWAGEN PASSAT brake

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Installing - Place protective seal with the outer sealing lip on
the piston. Note:
Hold piston in front of brake caliper housing. - Insert protective seal inner sealing lip into the
caliper housing groove using a screwdriver. Page 6 of 8Rear brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.4

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Note: - Thread piston into housing by turning knurled
wheel clockwise. Install special tool 3272 so that the collar (arrow)
of the tool is seated against the brake carrier. If piston is difficult to move, use a 13 mm open
end wrench on 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 is destroyed.
- Install brake pads. Page 7 of 8Rear brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.4

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Pre-bleeding brake caliper Note:
Position brake caliper as illustrated to pre-bleed. - Open bleeder valve and using a standard bleeder
bottle, fill with brake fluid until bubble-free brake
fluid flows from the threaded hole (brake hose
connection). Close bleeder screw. Page 8 of 8Rear brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.4

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Brake pressure regulator,
checking and adjusting

Vehicles without ABS, vehicles with
ABS, ABS/EDS, Teves 04 The brake pressure regulator is mounted on a bracket
which is in turn fixed to a rear axle mounting bracket
and is controlled from the rear axle by a spring.
Checking operation
Firmly depress the brake pedal and release quickly
(vehicle standing on its wheels). This must cause the
brake pressure regulator lever to move.
Checking and adjusting pressure
Note:
The brake pressure regulator is set with the vehicle
unladened 1)
.
1)
The term "unladen" means: The weight of the
vehicle ready for the road (full fuel tank, spare wheel,
tool kit and jack). Page 1 of 4Brake pressure regulator, checking and adjusting12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.5

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Note:
Bleeding brake system on vehicles with ABS Page 47-27 . - Lift vehicle and connect pressure gauges to front
left brake caliper and to rear right wheel
cylinder/caliper.
- Bleed both gauges. - Lower vehicle and bounce the rear of the vehicle
several times.
- Depress brake pedal and check pressures. - Compare figures attained with specifications
Page 47-25 and if necessary adjust. Page 2 of 4Brake pressure regulator, checking and adjusting12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.5

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Load dependent brake pressure regulator specifications Model / Version Bar (psi) Bar (psi)
Rear axle drum Front axle 50 (725) Front axle 100 (1450)
brakes Rear axle 30 - 36
(435 - 522) Rear axle 51 - 57
(740 - 827)
Rear axle disc Front axle 50 (725) Front axle 100 (1450)
brakes Rear axle 35 - 41
(508 - 595) Rear axle 56 - 62
(812 - 899)
Four wheel drive Front axle 50 (725) Front axle 100 (1450)
Rear axle 41 - 47
(595 - 682) Rear axle 66 - 72
(957 - 1044) Page 3 of 4Brake pressure regulator, checking and adjusting12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.5

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Adjusting regulator
Rear axle test pressure too high:

- Release tension on regulator spring. Rear axle test pressures too low:

- Tension regulator spring.
Note:
Do not adjust with brake pedal depressed,
therefore observe the following sequence:

- Read off figures.
- Release pedal.
- Adjust spring.
- Depress pedal again.
- Read off figures and if necessary, readjust.
- Remove pressure gauges and bleed brake
system Page 47-27 . Page 4 of 4Brake pressure regulator, checking and adjusting12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.5

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Brake system, bleeding

Brake system, bleeding (vehicles with
and without ABS, ABS/EDL)

Changing brake fluid
Repair Manual, Maintenance
Note:
Bleeding the brake system on vehicles with
ABS, ABS/EDL is performed as for vehicles
with conventional braking systems.
Only use new brake fluid conforming to US
standard FMVSS 116 DOT 4.
Genuine VW/Audi brake fluid conforms to this
specification.
Brake fluid is poisonous. Also due to its
corrosive effect brake fluid must not come into
contact with paintwork.
Brake fluid is hygroscopic, which means it
absorbs moisture from the ambient air and
should always be stored in air tight containers.
Rinse off spillages using plenty of water. Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Page 1 of 3Brake system, bleeding12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.6