1996 VOLKSWAGEN PASSAT piston

Downloaded from www.Manualslib.com manuals search engine 47-15

Rear brake caliper,
servicing
Note: Apply thin coat of brake
cylinder paste to brake
cylinder pistons and seal. When repairing install all
parts supplied in repair kit. New brake calipers are
filled with brake fluid and
are pre-bled. When repairing it is
essential to pre-bleed the
brake calipers (without
brake pads) before
installing in the vehicle
Page 47-21 1 - Self-locking bolts, 35
Nm (26 ft lb) Always replace When loosening and
tightening counter-hold on guide pin Page 1 of 8Rear brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.4

Downloaded from www.Manualslib.com manuals search engine 47-16

2 - Sealing ring Remove using a
screwdriver Page 47-19 3 - Piston with automatic
adjustment Removing and
installing Page 47-19 4 - Protective seal Pull outer sealing lip
onto piston Install inner sealing lip
in brake caliper
housing groove
Page 47-20 5 - Dust cap
6 - Bleeder valve Apply thin coat of
brake cylinder paste
before screwing in. Page 2 of 8Rear brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.4

Downloaded from www.Manualslib.com manuals search engine 47-19

Rear brake caliper piston, removing and
installing

Removing Note: - Thread piston out of brake caliper housing by
turning the knurled wheel counter-clockwise. If piston is difficult to move, use a 13 mm open
end wrench on the flats (arrow A) provided for this
purpose. Install special tool 3272 so that the collar (arrow)
is before the piston. Note:
Make sure that the surface of the cylinder is not
damaged during removal. - Remove seal with a screwdriver Page 5 of 8Rear brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.4

Downloaded from www.Manualslib.com manuals search engine 47-20

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

Downloaded from www.Manualslib.com manuals search engine 47-21
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

Downloaded from www.Manualslib.com manuals search engine 48-36

- Pull adhesive tape out of the housing Valve body sealing ring, removing - Pull toothed rod all the way to the left - Turn lock washer so that the opening of the circlip
(arrow) is in the groove of the housing
- Continue to turn the lock washer (direction of
rotation left or right) so that the circlip turns out of
the housing
- Pull toothed rod with toothed rod guide out of the
housing, pull off toothed rod guide and place
toothed rod so that toothed rod piston sealing ring
will not be damaged
1 - Needle nose pliers (standard commercial) - Lubricate toothed rod - Drive sealing ring upward A - Puller, e.g. Kukko 21/4 B - Driver When installing the puller -A- make sure that the
claws (arrow on illustration page 13) engage
properly under the sealing ring. The puller must not
be spread too wide because otherwise the seat for
the sealing ring and housing will be damaged or the
sealing ring can jam in the housing. Page 36 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-41

Sealing ring on toothed rod, replacing - Press pliers together with slight pressure on the
sealing ring
- Pry out sealing ring and O-ring A - Needle nose pliers (standard commercial) 1 - Toothed rod with piston 2 - Sealing rod 3 - O-ring Page 41 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-42

Sealing rings, installing on toothed rod
piston - Slide mounting sleeve on toothed rod - Pull O-ring over tool and install in groove of piston - Lubricate sealing ring with hydraulic oil, pull over
tool and install in groove of piston Page 42 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1