1996 VOLKSWAGEN PASSAT Spring

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11 - Backing plate
12 - Hex socket head bolt,
10 Nm (7 ft)
13 - Wheel cylinder Checking for leaks
Fig. 1 14 - Wedge To remove and install
the brake drum, push
upwards through a
wheel bolt hole
Page 46-18 15 - Push rod Lubricate contact
points with G 000 650
paste
16 - Locating spring Unhook with pliers Page 3 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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Brake shoes, removing and installing

Removing

- Remove brake drum.
- Remove spring plate.
- Unhook lower return spring.
- Remove brake shoes.
- Unhook parking brake cable. - Clamp brake shoes in vice. - Remove wedge spring. - Remove upper return spring. - Unhook locating spring. Page 5 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 - 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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- Attach wedge spring.
- Install springs and spring plates.
- Install brake drum and adjust wheel bearing
play. Adjusting wheel bearing play Page 42-20
- Firmly depress brake pedal once, this adjusts
the rear brakes. Page 7 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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4 - Brake hose bracket
5 - Hex socket head bolt,
65 Nm (48 ft lb)
6 - Self-locking bolt, 35
Nm (26 ft lb) Always replace When loosening and
tightening, counter-
hold on guide pin
7 - Guide pin
8 - Protective cap
9 - Pad retaining springs Always replace when
changing pads
10 - Backing plate ring Distance between ring
collar and backing
plate: 9.5 mm Page 2 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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24 - Wheel speed sensor
rotor Insert drift through
wheel bolt holes and
drive off Drive on with suitable
sleeve
25 - Hex bolt, 60 Nm (44 ft
lb)
26 - Dished spring washer Larger seating surface
towards backing plate
27 - Backing plate
28 - Stub axle
29 - Parking brake cable Adjusting parking
brake Page 46-36 30 - Spring clip Page 6 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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Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30
Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30 6 - Brake pedal return
spring
7 - Return spring
mounting tube
8 - Brake pedal mounting
bushing
9 - Brake pedal
10 - Clutch pedal Removing and
installing 11 - Pedal cluster mounting bracket
12 - Clutch pedal pivot pin
13 - Clutch pedal mounting
bushing
14 - Over-center spring
mounting
15 - Over-center spring Before removing,
remove clutch pedal Page 6 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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Brake pedal, removing and installing

Note:
Grease all mounting and contact surfaces with
MoS
2 grease.
To remove brake servo disconnect brake pedal
at clevis only.

Removing

- Before removing brake pedal remove trim
- Remove brake pedal clevis pin connection
securing clip.

- Remove pin.
- Remove brake pedal pivot pin securing clip.
- Remove pivot pin.
- Remove mounting sleeve, return spring
mounting tube with brake pedal.

Installing

- Install in reverse order. Page 8 of 9Parking brake lever assembly overview12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6