Front caliper piston, removing and installing

WARNING: This page is about a different variant/trim than selected.

Special tools and equipment

Fig 1: 3409 Wedge

Courtesy of VOLKSWAGEN UNITED STATES, INC.

3409 Wedge
Piston resetting tool

Removing

Fig 2: Identifying Brake Caliper Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Force piston out of brake caliper housing using compressed air.

NOTE: Place a piece of wood in the recess to prevent damaging the piston.

Fig 3: Removing Brake Caliper Seal Using Wedge 3409

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove seal using wedge 3409.

NOTE: When removing the piston seal make sure that the cylinder bore is not damaged.

Installing

The surface of the piston and seal must only be cleaned with methylated spirits and then dried.
Thinly coat piston and seal with assembly lubricant G 052 150 A2 before inserting.
Insert oil seal in brake caliper housing.

Fig 4: Identifying Protective Seal With The Outer Sealing Lip On The Piston

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place protective seal with the outer sealing lip on the piston.

Fig 5: Inserting The Inner Sealing Lip Into The Grove In The Cylinder Using Wedge 3409

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using wedge 3409, insert the inner sealing lip into the grove in the cylinder.

NOTE: Hold piston in front of caliper housing.

Fig 6: Pressing Piston Into The Brake Caliper Housing Using Piston Resetting Tool

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press piston into the brake caliper housing using piston resetting tool.

NOTE: The protective seal outer sealing lip must slip into the piston groove.

Special tools and equipment required

Fig 1: 3409 Wedge

Courtesy of VOLKSWAGEN UNITED STATES, INC.

3409 Wedge
Piston resetting tool

Removing

Fig 2: Forcing Piston Out Of Brake Caliper Housing Using Compressed Air

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Force piston out of brake caliper housing using compressed air.

NOTE: Place a piece of wood in the recess to prevent damaging the piston.

Only one piston at a time can be forced out. When doing this hold the other piston in the caliper using the piston resetting tool.

Fig 3: Removing Protective Seal Out Of Piston Groove Using Wedge 3409

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove protective seal out of piston groove using wedge 3409.
Remove piston.

NOTE: When removing ensure that the surface of the cylinder is not damaged.

Fig 4: Removing Protective Seal Using Wedge 3409

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove protective seal using wedge 3409.

Fig 5: Remove Seal Using Wedge 3409

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove seal using wedge 3409.

NOTE: When removing ensure that the surface of the cylinder is not damaged.

Installing

The surface of the piston and seal must only be cleaned with methylated spirits and then dried.

Fig 6: Identifying Oil Seal In Brake Caliper Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Thinly coat piston and seal with assembly paste G 052 150 A2 before inserting.
Insert oil seal in brake caliper housing.

Fig 7: Identifying Protective Seal With The Outer Sealing Lip On The Piston

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place protective seal with outer sealing lip on the piston.

Fig 8: Identifying Inner Sealing Lip In Groove In Cylinder

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using wedge 3409, insert inner sealing lip into groove in cylinder.

NOTE: When doing this hold piston in front of caliper housing.

Fig 9: Pressing Piston Into Brake Caliper Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press piston into brake caliper housing as far as possible by hand.

Fig 10: Identifying Piston In Brake Caliper Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press piston into brake caliper housing using piston resetting tool.

NOTE: The protective seal outer sealing lip will then locate in piston groove.