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

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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

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Parking brake lever
assembly overview
1 - Parking brake lever Different versions for
rear drum and disc
brakes Before removing
remove center console 2 - Hand grip Pry trim up with a
small screwdriver then
pull forward to remove
Fig. 2 3 - Adjusting nut Adjusting parking
brake:
- Vehicles with drum
brakes Page 46-26 - Vehicles with disc
brakes Page 46-36 Page 1 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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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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The parking brake cable is secured by clamps to the
axle beam in the center of the two colored marks
(arrow). Fig. 1 Parking brake cable installation
position Fig. 2 Hand grip, removing - Pry up parking brake cable trim with a screwdriver
and pull grip and trim off forward. Page 3 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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Fig. 3 Center console, removing - Remove rear ashtray (center console). - Remove console rear securing screws (arrows). Page 4 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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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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16 - Securing clip Ensure seated
securely
17 - Brake Light Switch Adjusting Page 46-45 Page 7 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