Recommended replacement interval for the part category Brake caliper : 100000 km

Important!

This replacement procedure can be used for:
VW Passat Alltrack (365) 2.0 TSI 4motion, VW Passat Alltrack (365) 1.8 TSI, VW Passat Alltrack (365) 1.8 TSI, VW Passat Alltrack (365) 2.0 TDI 4motion, VW Passat Alltrack (365) 2.0 TDI, VW Passat Alltrack (365) 2.0 TDI 4motion, VW Passat Alltrack (365) 2.0 TDI 4motion … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

Alternative products

Brake caliper

Replacement: brake caliper – VW PASSAT ALLTRACK (365). List of the tools you'll need:

                      Torque wrench
                    
                      Wire brush
                    
                      HEX bit  No.H7
                    
                      Drive socket # 11 
                    
                      Ratchet wrench
                    
                      Brake cleaner 
                    
                      Copper grease 
                    
                      Flat screwdriver
                    
                      Fluid container
                    
                      Anti-squeal paste
                    
                      Wheel impact socket #17
                    
                      Wheel chock 
                    
                      Brake hose clip
                    
                      Crow bar

Buy tools

Replacement: brake caliper – VW PASSAT ALLTRACK (365). Tip from AUTODOC:

The replacement procedure is identical for the left and right brake calipers on the same axle.
All work should be done with the engine stopped.

Replacement: brake caliper – VW PASSAT ALLTRACK (365). Recommended sequence of steps:

Step 1

Open the bonnet.

Step 2

Unscrew the brake fluid reservoir cap.

Step 3

Secure the wheels with chocks.
Step 4

Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 5

Raise the front of the car and secure on supports.

Step 6

Unscrew the wheel bolts.

Replacement: brake caliper – VW PASSAT ALLTRACK (365). AUTODOC recommends:
To avoid injury, hold up the wheel when unscrewing the bolts.
Step 7

Remove the wheel.
Step 8

Disconnect the ABS sensor electric socket. Disconnect the brake pad wear sensor plug. Remove the ABS sensor connector. Remove the connector of the brake pad wear sensor.

Please note!
Some cars are not equipped with the brake pad wear sensor.
Step 9

Put a container for gathering brake fluid beneath.
Step 10

Clean the area where the brake hose is connected to the caliper, and the guide pins area. Use a brake cleaner.

AUTODOC recommends:
After applying the spray, wait a few minutes.
Step 11.1

Clamp the brake hose off using a brake hose clamp.

Step 11.2

Unscrew the brake hose from the brake caliper. Use a drive socket #11. Use a ratchet wrench. Move the brake hose aside. Tie the brake hose to the car body with a hook or a piece of wire.
Step 12

Remove the dust boot caps of the brake caliper guide pins.
Step 13

Spread the brake pads. Use a crowbar.
Step 14

Using a simple screwdriver, remove the brake caliper spring clip.
Step 15

Unscrew the brake caliper fastening. Use HEX No.H7.
Step 16

Remove the brake caliper.

Replacement: brake caliper – VW PASSAT ALLTRACK (365). Professionals recommend:
When replacing the brake caliper, it is recommended to check the brake hose for damages and, if necessary, to replace it with a new one. If going to use the old brake pads, clean them.When replacing a brake caliper it is recommended to replace brake pads, check the state of the brake discs and replace them with new ones if necessary.
Step 17

Clean the brake caliper bracket from dirt and dust. Use a wire brush. Treat the brake caliper bracket. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake caliper – VW PASSAT ALLTRACK (365). After applying the spray, wait a few minutes.
Step 18

Remove the guide pins from the brake caliper.

Step 19

Clean old grease and rust stains, if there are any, from the caliper guide pins and guide pin boots. Use a brake cleaner.

Replacement: brake caliper – VW PASSAT ALLTRACK (365). Tip:
After applying the spray, wait a few minutes.
Step 20

Lubricate guide pins with special brake grease.

Replacement: brake caliper – VW PASSAT ALLTRACK (365). AUTODOC experts recommend:
If no new guide pins were supplied in a kit with the new brake calipers, use the old pins.
Step 21

Treat the contact surfaces between the brake pads and the brake caliper bracket. Use anti-squeal paste.
Step 22

Install the brake caliper together with the pads.

Please note!
Install the brake caliper starting with its lower part.
Step 23

Screw in the guide pins.

Replacement: brake caliper – VW PASSAT ALLTRACK (365). Tip from AUTODOC:
Hold up the brake caliper.
Step 24

Tighten the guide pins. Use HEX No.H7. Use a torque wrench. Tighten it to 30 Nm torque.
Step 25

Install the dust boot caps of the brake caliper guide pins.
Step 26

Install the brake caliper spring.
Step 27

Clean dirt from the brake hose bolt. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake caliper – VW PASSAT ALLTRACK (365). After applying the spray, wait a few minutes.
Step 28

Install and fix the brake hose into a new caliper. Use a drive socket #11. Use a torque wrench. Tighten it to 35 Nm torque.
Step 29

Remove the brake hose clamp.
Step 30

Connect the ABS sensor electric socket. Connect the brake pad wear sensor plug.

Replacement: brake caliper – VW PASSAT ALLTRACK (365). AUTODOC recommends:
Bleed the brake caliper system.
Step 31

Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
Step 32

Install the wheel.

AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. VW PASSAT ALLTRACK (365)
Step 33

Screw in the wheel bolts. Use wheel impact socket #17.
Step 34

Lower the car and working in a cross order, tighten the wheel bolts. Use a torque wrench. Tighten it to 120 Nm torque.
Step 35

Remove the jacks and chocks.

AUTODOC recommends:
Check the brake fluid level in the expansion tank and refill if necessary.
Step 36

Tighten the brake fluid reservoir cap. Close the hood.

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