brake VOLKSWAGEN PASSAT 1995 B3, B4 / 3.G Service Owners Manual

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Rear wheel brakes,
servicing (disc
brakes)
Girling rear wheel disc
brakes (front and four
wheel drive vehicles)
Note:
Only items 5, 6, 7, 8, 9, 10, 11
and 12 apply for four wheel
drive.
1 - Axle beam
2 - Hex socket head bolt,
10 Nm (7 ft lb)
3 - Wheel speed sensor Only for vehicles with
ABS Insert with lubricating
paste, G 000 650 Page 1 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 - 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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Repair Manual, Maintenance 11 - 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.
12 - Brake pads Thickness: 12 mm Checking thickness: Wear limit: 7mm
(including backing
plate) Always replace on
both sides Removing and
installing Page 46-33 13 - Brake caliper Servicing Page 47-15 Page 3 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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21 - Brake disc Brake disc diameter
for vehicles with front
wheel drive: 226 mm Removing and
installing Page 42-24 Brake disc diameter
for vehicles with four
wheel drive: 239 mm Removing and
installing Page 42-59 Brake disc thickness,
for both versions: 10
mm Wear limit: 8 mm When worn, always
replace on both sides Assembly sequence
for run-in brake discs:
- Brake caliper - Brake pads - Brake carrier 22 - Inner wheel bearing
23 - Seal Page 5 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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Brake pads, removing and installing

Note:
Mark brake pads when removing if they are to be
reused. Re-install in their original position to
prevent uneven braking!

Removing

- Remove wheels. - Remove parking brake cable from brake caliper
(arrow).
- Remove securing bolts from brake caliper housing; counter-hold on guide pins. - Remove brake pads. Page 7 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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Parking brake, adjusting (disc brakes)

Note:
Due to the self-adjusting rear brakes there is no
requirement to adjust the parking brake.
Adjustment is only necessary after replacing
parking brake cables, brake calipers, brake
pads and brake discs. Remove hand grip and central console to allow
access to adjusting nuts (arrows) Page 46-39 . - Parking brake lever in "off" position. Tighten
adjusting nut until lever (arrow) lifts off the brake
caliper stop.
- A gap of max. 1.5 mm from stop (arrow) is
permissible each side but should be set the same
on both sides.
- Pull parking brake on and then release again. - Check that both wheels turn freely. Page 10 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