1996 VOLKSWAGEN PASSAT piston

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Installing

Note:
Before inserting new brake pads, press piston
back into the cylinder with resetting tool. Before
pressing the piston back, remove some brake
fluid from the reservoir with a bleeder bottle. If
reservoir has been topped up, fluid may overflow
and cause damage. Note: - Press piston back. - Install brake pads. - Swing brake caliper housing down and tighten bolt. The repair kit contains two self-locking bolts which must always be installed. After replacing the brake pads, depress brake
pedal firmly several times with the vehicle
stationary so that the brake pads are properly
seated in their normal operating position. Page 7 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1

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Front brakes,
servicing
(Teves/Ate)
Repair Manual, Maintenance 1 - Screw
2 - Brake disc When worn always
replace on both sides Remove brake caliper
prior to removing Ventilated brake disc
diameter: 288 mm Brake disc thickness:
25 mm Wear limit: 23 mm 3 - Brake pads Always replace on
both sides Pads are different; pad on piston side has
retaining spring Removing and
installing Page 46-12 Pad thickness: 14 mm Checking thickness Wear limit: 7 mm
(including backing
plate) Page 1 of 7Front brakes, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.2

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Installing
Note:
Before installing new brake pads, press piston back
into the cylinder with resetting tool. Before pressing
the piston back, remove some brake fluid from the
reservoir with a bleeder bottle. If reservoir has been
topped up, fluid may overflow and cause damage. - Remove both guide pins from brake caliper. - Remove brake caliper housing and lay to one side
so that weight of brake caliper does not stress or
damage brake hose.
- Take brake pads out of brake caliper housing or
from brake carrier. - Pressing piston back. Page 6 of 7Front brakes, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.2

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- Install brake pad with retaining spring in brake
caliper housing (piston).

- Install outer brake pad in brake carrier.
- Secure brake caliper housing with both guide
pins to brake carrier.

- Install both protective caps.
- Install retaining spring into brake caliper
housing.

Note:
After replacing the brake pads, depress brake
pedal firmly several times with the vehicle
stationary, so that the brake pads are proper/y
seated in their normal operating position. Page 7 of 7Front brakes, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.2

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Installing - Connect locating spring and install brake shoes on
the push rod.
- Insert wedge. - Insert brake shoe with brake lever in push rod. - Connect upper return spring. - Connect parking brake cable to brake lever. - Place brake shoes on wheel cylinder pistons. - Connect lower return spring and lift brake shoes
onto lower support. Page 6 of 8Rear wheel brakes, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.4

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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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Girling front brake
caliper, servicing
Note: When repairing install all
parts supplied in repair kit. Apply thin coat of brake
cylinder paste to brake
cylinders, pistons and
sea/s.
1 - Protective seal
2 - Bleed valve Apply thin coat of brake cylinder paste to threads before
screwing in
3 - Brake caliper housing
4 - Self-locking hex bolt,
35 Nm (26 ft lb) Always replace When loosening and
tightening counter-hold on guide pin Page 1 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2

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5 - Seal Remove using a
screwdriver Page 47-7 6 - Piston Removing and
installing Page 47-7 Apply thin coat of
brake cylinder paste
before inserting
7 - Protective seal Do not damage when
inserting piston
8 - Brake carrier with
guide pins and
protective caps 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 Page 2 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2