lock VOLKSWAGEN PASSAT 1995 B3, B4 / 3.G Service Repair Manual

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Rear wheel brakes,
servicing (drum
brakes)
Notes Page 42-15 1 - Grease cap Removing and
installing from
Page 42-19 2 - Cotter pin Always replace 3 - Locking ring
4 - Hex nut Adjusting wheel
bearing play Page 42-20 5 - Thrust washer Page 1 of 4Rear wheel brakes, servicing (drum brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.3

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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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14 - Outer wheel bearing
15 - Hex nut Adjusting wheel
bearing play Using a screwdriver it
must be possible to
move the thrust
washer by finger
pressure (without
leverage) Page 42-20 Secure with locking
ring and new cotter pin 16 - Cotter pin Always replace 17 - Grease cap Removing and
installing Page 42-29 18 - Lock ring
19 - Thrust washer
20 - Wheel bolt, 110 Nm (81
ft lb) Page 4 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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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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Brake pedal/brake servo,
removing and installing
CAUTION!
The brake pedal travel must
not be restricted by
additional floor coverings.
Note:
Grease all mountings before
installing with G 000 602
grease.
1 - Securing clip Ensure securely
seated
2 - Pin
3 - Brake servo push rod
clevis
4 - Self-locking hex nut, 20 Nm (15 ft lb)
5 - Brake pedal pivot pin Page 5 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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Assembly
overview: brake
master
cylinder/brake
servo
Note:
Brake master cylinders and
brake servos from different
manufacturers are installed.
Complete master cylinders and
brake servos can be replaced
independently of each other.
1 - Seal For brake servo 2 - Self-locking hex nut, 20 Nm (15 ft lb)
3 - Mounting bracket
4 - Mounting bracket For brake servo 5 - Seal Page 1 of 4Assembly overview: brake master cylinder/brake servo12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.1

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7 - Sealing ring Always replace 8 - Self-locking hex nut, 20 Nm (15 ft lb)
9 - Brake master cylinder Cannot be repaired. If
faulty, replace
complete.
10 - Sealing plug Moisten with brake
fluid and press into
reservoir
11 - Seal Page 3 of 4Assembly overview: brake master cylinder/brake servo12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.1

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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