Front brake caliper piston, removing and installing

Special tools, testers and auxiliary items required

Fig 1: Disassembly Wedge VAS 3409

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig 2: Assembly Device For Protective Cap T10146/5

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

Fig 3: Using Compressed Air To Force Piston Out Of Brake Caliper Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Fig 4: Removing Seal With Trim Removal Wedge 3409

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Installing

The surface of piston and seal must only be cleaned with mineral spirits and then dried.
Thinly coat piston and seal with assembly paste before inserting.

Fig 5: Installing Sealing Ring In Brake Caliper

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig 6: Pressing Protective Cap With Assembly Tool And Piston Resetting Tool Into Brake Caliper

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Use protective backings

Fig 7: Pressing Protective Cap Onto Brake Caliper Housing So That It Contacts Brake Caliper Housing All Around

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press protective cap onto brake caliper housing so that it contacts brake caliper housing all around.
It should no longer be possible to remove protective cap from brake caliper housing by hand.
Thinly coat piston and seal with assembly paste before inserting.

Fig 8: Lifting Up Piston With Standard Extension And Ratchet Attachment

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lift brake piston, as shown, with commercially available extension and ratchet adapter and lightly press against protective cap.

Do not angle piston, to avoid damaging protective cap.

Blow protective cap on with pressurized air (max. 3 bar). The protective cap will thereby jump over brake piston.

Use protective backings

NOTE:

The inner sealing lip of the protective cap thereby slips into the groove on the piston.