Brake pads, removing and installing

Fig 1: Identifying Special Tools - Brake Pads, Removing And Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Reset and screw out tool 3272 or
Resetting extracting tool T10165
Torque wrench VAS 5820
Ratchet V.A.G 1410/3

Socket T40027

Removing

NOTE:

Mark brake pads when removing them if they are to be reused. Reinstall in their original position to prevent uneven braking.

Raise vehicle.
Remove wheels.

Fig 2: Removing/Installing Securing Bolts From/To Brake Caliper Housing, While Counter-Holding On Guide Pins

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Remove securing bolts from brake caliper housing, while counter-holding on guide pins.

NOTE:

To replace the lower brake caliper bolt on quattro versions, first disengage the brake cable.

NOTE:

On RS-4 model 8EC, do not loosen upper bolt with damper and only fold brake caliper up to change brake pad.

Fig 3: Removing/Installing Retaining Clip And Disconnecting/Connecting Parking Brake Cables At Brake Caliper

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Remove retaining clip - 1 - and disconnect parking brake cables at brake caliper.
Remove brake caliper housing and lay to one side so that the weight of the brake caliper does not stress or damage the brake hose.

Fig 4: Identifying Brake Pads, Guide Clips & Brake Caliper Housing

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Remove brake pads.
Remove guide clips.
Remove brake pads from housing.
Clean brake caliper housing, especially brake pad contact surface.

Use methylated spirits to clean the brake caliper housing.

NOTE:

Press piston back into the cylinder with resetting tool, before inserting new brake pads. Draw off brake fluid from the reservoir with a bleeder bottle before pressing piston back. Otherwise brake fluid which was used to top off brake fluid reservoir, may run out and cause damage.

CAUTION: Brake fluid is poisonous and must never be extracted by mouth using a hose!

Installing

Use methylated spirits to clean the brake caliper housing.

Fig 5: Screwing In Piston By Turning Reset And Screw Out Tool 3272 Clockwise

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Screw in piston by turning reset and screw out tool 3272 clockwise.

Fig 6: Inserting Pad Retaining Springs

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Insert pad retaining springs.

Fig 7: Identifying Brake Pads, Guide Clips & Brake Caliper Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install brake pads.

Fig 8: Identifying Brake Pads Are Located Correctly In Anti-Rattle Springs

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Make sure that the brake pads are located correctly in the anti-rattle springs - arrows -.

NOTE:

The repair kit includes four self-locking hex bolts which must be installed in all cases.

Fig 9: Removing/Installing Securing Bolts From/To Brake Caliper Housing, While Counter-Holding On Guide Pins

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure brake caliper housing with new self-locking bolts.
Make sure not to twist the brake hose when installing.
Tighten bolts on brake caliper housing, 35 Nm.
Install brake cable.

NOTE:

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.

Mounting wheels → 44 - WHEELS, TIRES, VEHICLE ALIGNMENT .

Check brake fluid level and top off if necessary.