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

Important!

This replacement procedure can be used for:
VW PASSAT Variant (3B6) 2.8 4motion, VW PASSAT Variant (3B6) 2.8 … View more

The steps may slightly vary depending on the car design.

How to change front brake caliper on VW PASSAT 5 (B5) [TUTORIAL AUTODOC]

Alternative products

Brake caliper

Replacement: brake caliper – VW Passat B5 Variant. Tools you need:

                      Wire brush
                    
                      Brake cleaner 
                    
                      Copper grease 
                    
                      Combination spanner #10
                    
                      Combination spanner #11
                    
                      Drive socket # 10 
                    
                      Drive socket # 11 
                    
                      HEX bit no.H7.
                    
                      Wheel impact socket #17
                    
                      Ratchet wrench
                    
                      Torque wrench
                    
                      Fluid container
                    
                      Brake hose clip
                    
                      Brake bleeder kit
                    
                      Crow bar
                    
                      Wheel chock

Buy tools

Replacement: brake caliper – VW Passat B5 Variant. AUTODOC recommends:

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 B5 Variant. Take the following steps:

Step 1

Open the bonnet. Unscrew the brake fluid reservoir cap.
Step 2

Secure the wheels with chocks.
Step 3

Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 4

Raise the front of the car and secure on supports.
Step 5

Unscrew the wheel bolts.

Replacement: brake caliper – VW Passat B5 Variant. Tip:
To avoid injury, hold up the wheel when unscrewing the bolts.
Step 6

Remove the wheel.
Step 7

Disconnect the ABS sensor electric socket. Disconnect the brake pad wear sensor plug. Use a crowbar.

Please note!
Some cars are not equipped with the brake pad wear sensor.
Step 8

Clamp the brake hose off using a brake hose clamp.
Step 9

Put a container for gathering brake fluid beneath.
Step 10

Clean the brake pipe fastener. Use a wire brush. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake caliper – VW Passat B5 Variant. After applying the spray, wait a few minutes.
Step 11

Unscrew the fastener connecting the brake pipe to the brake hose. Use a combination spanner #11.
Step 12

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

Unscrew the brake caliper fastening. Use HEX No.H7. Use a ratchet wrench.
Step 14

Detach the brake caliper retaining spring. Use a crowbar.
Step 15

Remove the brake caliper.

Replacement: brake caliper – VW Passat B5 Variant. Professionals recommend:
Make sure that the brake caliper is not hanging on the brake hose.Don't press the brake pedal after the brake caliper has been removed. As a result, the piston can fall out from the brake cylinder, and brake fluid leakage and depressurization of the system may occur. Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.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. 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 16

Remove the brake pads.

Step 17

Clean the brake caliper surface. Use a wire brush. Use a brake cleaner.

AUTODOC recommends:
After applying the spray, wait a few minutes.
Step 18

Unscrew the brake hose fastening bracket from the brake caliper. Use a drive socket #11. Use a ratchet wrench.
Step 19

Unscrew the fastener connecting the brake pipe to the brake caliper. Use a combination spanner #11.
Step 20

Treat the brake pipe. Use a brake cleaner.

Replacement: brake caliper – VW Passat B5 Variant. Tip:
After applying the spray, wait a few minutes.
Step 21

Screw in the fastener connecting the brake pipe to the brake caliper. Use a combination spanner #11.
Step 22

Secure the brake hose fastening bracket. Use a drive socket #11. Use a ratchet wrench.
Step 23

Install the brake pads.

Replacement: brake caliper – VW Passat B5 Variant. Tip from AUTODOC experts:
If going to use the old brake pads, clean them.
Step 24

Install the brake caliper and fix it. Use HEX No.H7. Use a torque wrench. Tighten it to 25 Nm torque.
Step 25

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

Treat the brake hose. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake caliper – VW Passat B5 Variant. After applying the spray, wait a few minutes.
Step 27

Screw in the fastener connecting the brake pipe to the brake hose. Use a combination spanner #11.
Step 28

Remove the brake hose clamp.
Step 29

Connect the ABS sensor electric socket. Connect the brake pad wear sensor plug.
Step 30

Install the brake caliper retaining spring.
Step 31

Secure the brake bleeder kit.
Step 32

Undo the brake bleeder screw. Use a combination spanner #10.
Step 33

Connect the brake bleeder kit to the brake bleeder screw.
Step 34

Bleed the brake caliper system. Without starting the engine, press the brake pedal several times until you feel significant resistance.
Step 35

Tighten the brake bleeder screw. Use a combination spanner #10.
Step 36

Disconnect the brake bleeder kit.
Step 37

Tighten the brake caliper bleed screw. Use a drive socket #10. Use a torque wrench. Tighten it to 9 Nm torque.
Step 38

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 39

Clean the brake disk surface. Use a brake cleaner.

Replacement: brake caliper – VW Passat B5 Variant. AUTODOC experts recommend:
After applying the spray, wait a few minutes.
Step 40

Install the wheel.

AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. VW Passat B5 Variant
Step 41

Screw in the wheel bolts. Use wheel impact socket #17.
Step 42

Lower the car and working in a cross order, tighten the wheel bolts. Use a torque wrench. Tighten it to 120 Nm torque.
Step 43

Remove the jacks and chocks.

Replacement: brake caliper – VW Passat B5 Variant. AUTODOC recommends:
Check the brake fluid level in the expansion tank and refill if necessary.
Step 44

Tighten the brake fluid reservoir cap. Close the hood.

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