VW Rear Brake Servicing Guide

Rear brake, servicing Стр.
1 из 30
46 - 2
Rear brake, servicing

Caution!
This document contains Volkswagen World Wide

content. Not all of the information applies to the US
and Canadian Market.
Rear brake C 38, servicing
Note:
After replacing brake pads, depress brake pedal

several times firmly to properly seat brake pads in
their normal operating position.
Use brake filler/bleeder unit VAS 5234 or extraction

device V.A.G 1869/4 to extract brake fluid from
brake fluid reservoir.
Before removing brake caliper or disconnecting

brake hose, brake pedal depressor V.A.G 1869/2
must be inserted (this dissipates pressure).
Rear brake, servicing Стр. 2 из 30
ABS wheel speed sensor
Before inserting sensor,

clean inner surface of bore
hole and coat with hot bolt
paste G 052 112 A3
Hex socket head bolt, 8 Nm
Multi-point socket head bolt, 90

Nm plus an additional 90 (1/4
turn)
Always replace after

removal
Wheel bearing housing
Cover plate
Hex head bolt, 9 Nm/Torx bolt,

12 Nm
Hex head bolt M6x10

changed from Torx bolt
M6x12
Replace hex head bolt with

hex head bolt and Torx bolt
with Torx bolt
Wheel bearing/hub unit
Brake disc
Dia. 255 mm
Thickness: 10 mm
Wear limit: 8 mm
Always replace pads on both

sides of axle if worn.
Remove brake caliper before

removing
Phillips head screw, 4 Nm
Bolt
Brake pads
Thickness: 11 mm without
backing plate
Wear limit: 2 mm without

backing plate
Checking thickness
Repair Manual, Maintenance
Always replace together on

both sides of axle
Removing and installing

46-2, Brake pads, removing
and installing
Brake carrier with guide pins

and protective cap
Supplied as pre-assembled
replacement part with
sufficient grease on guide
pins
If protective caps or guide

pins are damaged, install
repair kit. Use supplied
grease packet to lubricate
guide pins
Brake caliper
Do not remove brake hose

when replacing brake pad

46-2, Brake caliper,
removing and installing
Servicing 47-2, Rear

brake caliper, servicing
After servicing or replacing,

parking brake cable must be
adjusted first.
Adjusting parking brake

46-2, Parking brake,
adjusting
Hose retainer
Brake line, 14 Nm
Hex bolt, self-locking, 35 Nm
Replace
Parking brake cable

adjusting
Spring clamp
Brake hose
Brake pads, removing and installing
Special tools, testers and auxiliary items required

Torque wrench V.A.G 1331
Piston compressing and extracting tool T 10165
Removing
When removing, mark brake pads that will be used

again. Install in same position, otherwise braking
effect will be uneven!
- Remove wheels.
- Counter-hold guide pins and remove attachment bolts

from brake caliper.
- Remove brake caliper and secure with wire so that the

weight of the brake caliper does not burden or damage

brake hose.
- Remove brake pads.
Cleaning:
Warning!
Do not blow brake system using compressed air, the

dust produced is harmful to health!
- Thoroughly clean contact surfaces for brake pads at

brake carrier, remove corrosion.
- Clean brake caliper, especially adhesive surfaces for

brake pads, they must be free of residual adhesive and
grease.
Use only appropriate solvents for cleaning brake

caliper.
Installing
Before pushing back piston, extract some of brake

fluid out of brake fluid reservoir using a bleeder bottle.
Otherwise, especially if reservoir has been topped off,
fluid will overflow and cause damage.
- Install pistons at knurling wheel of reset and screw out

tool T 10165 by turning toward right. Do not damage
protective caps.
- Use special tool 10165/1 for assistance when installing.
For pistons that are difficult to move, an open-end

wrench (size 13 mm) can be applied at the
appropriate wrench surface - arrow A - .
- Remove protective foil on brake pad backing plates.

- Insert brake pads in brake carrier.
When installing brake caliper, make sure that brake pads

are not affixed to brake caliper before correct installation
position has been reached.
- Secure brake caliper using new self-locking bolts.
The repair kit includes four self-locking hex bolts

which must be installed in all cases.
- Install wheels.
Torque specification for wheel bolts
Repair Manual, Suspension, Wheels, Steering, Repair

Group 44,
Note:
After replacing brake pads and before moving

vehicle, always depress brake pedal several times
firmly to properly seat brake pads in their normal
operating position.
Check brake fluid level after replacing brake pad.
Tightening torque:
Hex bolt, brake caliper to brake carrier 35 Nm
Use new bolts!
Brake caliper, removing and installing

Brake pedal actuator V.A.G 1869/2
Removing
Work procedure applies only for replacing or when

performing subsequent service work on brake caliper.
- Remove wheels.
- Unhook brake cable from lever on brake caliper.
- Remove spring clip and pull brake cable from holder on

brake caliper.
- Connect bleeder hose of bleeder bottle to bleeder valve

of brake caliper and then open bleeder valve.
- Insert brake pedal depressor V.A.G 1869/2 .
- Close bleeder valve and remove bleeder bottle.
- Remove brake line.

- Remove both mounting bolts from brake caliper, when

doing this, counterhold on guide pin.
- Remove brake caliper from brake carrier.
Installing
Piston is pressed back.
Brake pads sit on brake carrier.
- Secure brake caliper on brake carrier using new self-

locking bolts.
- Install brake line on brake caliper.
- Bleed braking system 47-4, Bleeding braking system
- Hook in brake cable and secure it to holder with spring

clip.
- Adjusting parking brake 46-2, Parking brake,

adjusting
- Install wheels.

Group 44,
Note:
Before moving vehicle, depress brake pedal several

times firmly to properly seat brake pads in their
normal operating position.
Check brake fluid level.
Tightening torques:
Use new bolts!
Brake line to brake caliper 14 Nm
Rear wheel brake CII 38, servicing
Note:




paste G 052 112 A3

turn)

removal
Cover plate
Torx bolt, 12 Nm

Brake disc
Dia. 286 mm
Thickness: 12 mm
Wear limit: 10 mm


removing
Bolt
Only on front wheel drive
Brake pads
Thickness: 11 mm without
backing plate

backing plate
Checking thickness

both sides of axle

and installing
Brake carrier with guide pins

and protective cap
pins

guide pins
Anti-rattle spring
Always replace when pads

are replaced
Brake caliper




adjusted first.

adjusting
Hose retainer
Brake line, 14 Nm
Replace
Parking brake cable

adjusting
Spring clamp
Brake hose

Removing

- Remove wheels.

from brake caliper.

weight of brake caliper does not burden or damage brake

hose.
- Remove brake pads and anti-rattle springs - arrows - .
Cleaning:
Warning!

- Contact surfaces between brake pads and brake carrier

must be cleaned, remove corrosion.
- Clean brake caliper.

caliper.
Installing
Before pushing back piston, extract some of brake

fluid out of brake fluid reservoir using a bleeder bottle.
Otherwise, especially if reservoir has been topped off,
fluid will overflow and cause damage.

protective caps.

- Insert brake pad retention plates - arrows - and brake

pads in brake carrier.
- Make sure that the brake pads are located correctly in

anti-rattle springs - arrows - .

- Install wheels.

Group 44,
Note:

operating position.
Tightening torque:
Use new bolts!
Removing

- Remove wheels.

brake caliper.
- Connect bleeder hose of bleeder bottle to brake caliper

bleeder valve and then open bleeder valve.

Installing
Brake pads sit in retaining springs on brake carrier.

locking bolts.

clip.

adjusting
- Install wheels.


Group 44,
Note:

Tightening torques:
Use new bolts!
Rear wheel brake CII 41, servicing
Note:



I - Front wheel drive, assembly overview
II - All wheel drive differences


paste G 052 112 A3

turn)

removal
Cover plate
Hex head screw, 9 Nm/Torx

screw 12 Nm
Hex head bolt M6x10

changed from Torx bolt
M6x12
Replace hex head bolt with

hex head bolt and Torx bolt
with Torx bolt
Brake disc
Diameter 15 inch: 260 mm,

17 inch: dia. 310 mm
Thickness, 15 inch: 12 mm,

17 inch: 22 mm
Wear limit, 15 inch: 10 mm,

17 inch: 20 mm


removing
Bolt
Only on front wheel drive
Brake pads
Thickness 11 mm without
backing plate

backing plate
Checking thickness

both sides of axle

and installing
Brake carrier with different guide

pins and protective cap
pins

guide pins
Assembly guide: 46-2,

Assembly guide, brake
carrier CII 41 15 inch from
KW 32/04:
Anti-rattle spring
Always replace when pads

are replaced
Brake caliper




adjusted first.

adjusting
Hose retainer
Brake line, 14 Nm
Replace
Parking brake cable

adjusting
Spring clamp
Brake hose
Assembly guide, brake carrier CII 41 15 inch from KW

32/04:
Short guide pins with stepping - arrows - , inlet

side.
Longer guide pins, outgoing.
Vibration dampener, outgoing.

Removing

- Remove wheels.

from brake caliper.

weight of the brake caliper does not burden or damage
brake hose.
- Remove brake pads and anti-rattle springs - arrows - .
Cleaning:
Warning!

- Contact surfaces between brake pads and brake carrier

must be cleaned, remove corrosion.
- Clean brake caliper.

caliper.
Installing
Before pushing back the piston, extract some of the

brake fluid out of brake fluid reservoir using a bleeder
bottle. Otherwise, especially if reservoir has been
topped off, fluid will overflow and cause damage.

protective caps.

- Insert brake pad retention plates - arrows - and brake

pads in brake carrier.
- Make sure that the brake pads are located correctly in

anti-rattle springs - arrows - .

- Install wheels.

Group 44,
Note:

operating position.
Tightening torque:
Use new bolts!
Removing

- Remove wheels.

brake caliper.
- Connect bleeder hose of bleeder bottle to brake caliper

bleeder valve and then open bleeder valve.

Installing
Brake pads sit in retaining springs on brake carrier.

locking bolts.

clip.

adjusting
- Install wheels.

Group 44,
Note:

Tightening torques:
Use new bolts!
Parking brake, adjusting
A new adjustment is necessary only after replacing brake

cables, brake calipers or brake discs.
- Remove center console
Repair Manual, Body Interior, Repair Group 68,
- Operate foot brake forcefully at least three times.
- Apply parking brake 3 times and then release.
Parking brake lever in released position.

- Tighten adjustment nut - arrow (close-up) - ...
- ...until lever - 1 - on brake calipers lift off from stop - 2 -

.
- The distance - a - to stop - 2 - at left and right brake

pads together must not fall short 1 mm and not exceed 3
mm.
- Check whether wheels turn freely.
Due to the automatic rear brake adjuster, there is no need

to adjust parking brake after making initial adjustment.

VW Rear Brake Servicing Guide

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Rear brake, servicing Стр.

Rear brake, servicing

This document contains Volkswagen World Wide

Rear brake C 38, servicing

 After replacing brake pads, depress brake pedal

 Use brake filler/bleeder unit VAS 5234 or extraction

 Before removing brake caliper or disconnecting

 ABS wheel speed sensor

 Before inserting sensor,

 Hex socket head bolt, 8 Nm

 Multi-point socket head bolt, 90

 Always replace after

 Wheel bearing housing

 Hex head bolt, 9 Nm/Torx bolt,

 Hex head bolt M6x10

 Replace hex head bolt with

 Wheel bearing/hub unit

 Always replace pads on both

 Remove brake caliper before

 Phillips head screw, 4 Nm

 Wear limit: 2 mm without

Repair Manual, Maintenance

 Always replace together on

 Removing and installing

 Brake carrier with guide pins

 If protective caps or guide

 Do not remove brake hose

 Removing and installing

 Servicing 47-2, Rear

 After servicing or replacing,

 Adjusting parking brake

 Hex bolt, self-locking, 35 Nm

 Parking brake cable

 Adjusting parking brake

Brake pads, removing and installing

Special tools, testers and auxiliary items required

 Torque wrench V.A.G 1331

 Piston compressing and extracting tool T 10165

When removing, mark brake pads that will be used

- Counter-hold guide pins and remove attachment bolts

- Remove brake caliper and secure with wire so that the

weight of the brake caliper does not burden or damage

- Remove brake pads.

Do not blow brake system using compressed air, the

- Thoroughly clean contact surfaces for brake pads at

- Clean brake caliper, especially adhesive surfaces for

Use only appropriate solvents for cleaning brake

Before pushing back piston, extract some of brake

- Install pistons at knurling wheel of reset and screw out

- Use special tool 10165/1 for assistance when installing.

 For pistons that are difficult to move, an open-end

- Remove protective foil on brake pad backing plates.

- Insert brake pads in brake carrier.

When installing brake caliper, make sure that brake pads

- Secure brake caliper using new self-locking bolts.

 The repair kit includes four self-locking hex bolts

Torque specification for wheel bolts

Repair Manual, Suspension, Wheels, Steering, Repair

 After replacing brake pads and before moving

 Check brake fluid level after replacing brake pad.

 Use new bolts!

Brake caliper, removing and installing

Special tools, testers and auxiliary items required

After replacing brake pads, depress brake pedal

Use brake filler/bleeder unit VAS 5234 or extraction

Before removing brake caliper or disconnecting

ABS wheel speed sensor

Before inserting sensor,

Hex socket head bolt, 8 Nm

Multi-point socket head bolt, 90

Always replace after

Wheel bearing housing

Hex head bolt, 9 Nm/Torx bolt,

Hex head bolt M6x10

Replace hex head bolt with

Wheel bearing/hub unit

Always replace pads on both

Remove brake caliper before

Phillips head screw, 4 Nm

Wear limit: 2 mm without

Always replace together on

Removing and installing

Brake carrier with guide pins

If protective caps or guide

Do not remove brake hose

Removing and installing

Servicing 47-2, Rear

After servicing or replacing,

Adjusting parking brake

Hex bolt, self-locking, 35 Nm

Parking brake cable

Adjusting parking brake

Torque wrench V.A.G 1331

Piston compressing and extracting tool T 10165

For pistons that are difficult to move, an open-end

The repair kit includes four self-locking hex bolts

After replacing brake pads and before moving

Check brake fluid level after replacing brake pad.

Use new bolts!

Torque wrench V.A.G 1331

Brake pedal actuator V.A.G 1869/2

Piston is pressed back.

Brake pads sit on brake carrier.

Before moving vehicle, depress brake pedal several

Check brake fluid level.

Use new bolts!

After replacing brake pads, depress brake pedal

Use brake filler/bleeder unit VAS 5234 or extraction

Before removing brake caliper or disconnecting

ABS wheel speed sensor

Before inserting sensor,

Hex socket head bolt, 8 Nm

Multi-point socket head bolt, 90

Always replace after

Wheel bearing housing

Wheel bearing/hub unit

Always replace pads on both

Remove brake caliper before

Phillips head screw, 4 Nm

Only on front wheel drive

Wear limit: 2 mm without

Always replace together on

Removing and installing

Brake carrier with guide pins

If protective caps or guide

Always replace when pads

Do not remove brake hose

Removing and installing

Servicing 47-2, Rear

After servicing or replacing,

Adjusting parking brake

Hex bolt, self-locking, 35 Nm

Parking brake cable

Adjusting parking brake

Torque wrench V.A.G 1331

Piston compressing and extracting tool T 10165