Recommended replacement interval for the part category Brake disc : 50000 km

Important!

This replacement procedure can be used for:
VW Passat Alltrack (3G5, CB5) 2.0 TDI 4motion, VW Passat Alltrack (3G5, CB5) 2.0 TSI 4motion, VW Passat Alltrack (3G5, CB5) 2.0 TSI 4motion, VW Passat Alltrack (3G5, CB5) 1.4 TSI 4motion, VW Passat Alltrack (3G5, CB5) 2.0 TDI 4motion, VW Passat Alltrack (3G5, CB5) 2.0 TDI 4motion, VW Passat Alltrack (3G5, CB5) 2.0 TDI 4motion, VW Passat Alltrack (3G5, CB5) 2.0 TDI 4motion, VW Passat Alltrack (3G5, CB5) 2.0 TSI 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

All the parts you need to replace – Brake Discs for Passat Alltrack (3G5, CB5) and other VW models

Brake disc

        Brake disc for VW Passat Alltrack (3G5, CB5) 2.0 TSI 4motion Petrol (220 hp)
      
        Brake disc for VW Passat Alltrack (3G5, CB5) 2.0 TDI 4motion Diesel (150 hp)
      
        Brake disc for VW Passat Alltrack (3G5, CB5) 2.0 TDI 4motion Diesel (190 hp)
      
        Brake disc for VW Passat Alltrack (3G5, CB5) 2.0 TDI 4motion Diesel (240 hp)
      
        Brake disc for VW Passat Alltrack (3G5, CB5) 2.0 TDI 4motion Diesel (184 hp)
      
        Brake disc for VW Passat Alltrack (3G5, CB5) 1.4 TSI 4motion Petrol (150 hp)
      
        Brake disc for VW Passat Alltrack (3G5, CB5) 2.0 TSI 4motion Petrol (272 hp)
      
        Brake disc for VW Passat Alltrack (3G5, CB5) 2.0 TSI 4motion Petrol (280 hp)
      
        Brake disc for VW Passat Alltrack (3G5, CB5) 2.0 TDI 4motion Diesel (200 hp)

Replacement: brake discs – VW PASSAT ALLTRACK (3G5). List of the tools you'll need:

                        Wire brush
                      
                        Nylon cleaning brush
                      
                        WD-40 spray
                      
                        Brake cleaner 
                      
                        Copper grease 
                      
                        Torque wrench
                      
                        Drive socket # 21 
                      
                        HEX bit No.H7
                      
                        Torx bit T27
                      
                        Torx bit T30
                      
                        Wheel impact socket #17
                      
                        Ratchet wrench
                      
                        Tap wrench
                      
                        Rubber mallet
                      
                        Impact screwdriver
                      
                        Brake caliper wind back tool
                      
                        Crow bar
                      
                        Wheel chock

Buy tools

AUTODOC recommends:

Replace the brake disks on the car VW PASSAT ALLTRACK (3G5) in complete set for each axis. Regardless of the state of components. This will ensure even braking.
The replacement procedure is identical for both brake disks on the same axle.
When changing the brake discs, always replace the brake pads.
Please note: all work on the car – VW PASSAT ALLTRACK (3G5) – should be done with the engine switched off.

Carry out replacement in the following order:

Step 1

Open the hood.

Step 2

Clean the brake fluid reservoir cap. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake discs – VW PASSAT ALLTRACK (3G5). After applying the spray, wait a few minutes.
Step 3

Unscrew the engine solenoid valve bracket. Use Torx T27. Use a ratchet wrench.
Step 4

Unscrew the brake fluid reservoir cap.
Step 5

Secure the wheels with chocks.

Step 6

Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 7

Raise the front of the car and secure on supports.

Step 8

Unscrew the wheel bolts.

AUTODOC recommends:
Important! Hold the wheel while unscrewing the fastening bolts. VW PASSAT ALLTRACK (3G5)
Step 9

Remove the wheel.
Step 10

Spread the brake pads. Use a crowbar.
Step 11

Remove the dust boot caps of the brake caliper guide pins. Use a crowbar.
Step 12

Unscrew the brake caliper fastening. Use HEX No.H7. Use a ratchet wrench.
Step 13

Detach the brake caliper retaining spring. Use a crowbar.
Step 14

Remove the brake caliper.

Replacement: brake discs – VW PASSAT ALLTRACK (3G5). Tip:
Tie the caliper to the suspension or to the body with a wire without disconnecting from the brake hose to prevent depressurization of the brake system.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.
Step 15

Remove the brake pads.
Step 16

Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
Step 17

Unscrew the caliper bracket fastening. Use a drive socket #21. Use a ratchet wrench. Use a tap wrench.
Step 18

Remove the caliper bracket.
Step 19

Clean the brake disc fastener. Use a wire brush. Use WD-40 spray.
Step 20

Unscrew the brake disc fastening. Use Torx T30. Use an impact screwdriver.
Step 21

Remove the brake disc. Use a rubber mallet.
Step 22

Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
Step 23

Install the brake disc.
Step 24

Tighten the brake disc fastening. Use Torx T30. Use a torque wrench. Tighten it to 4 Nm torque.
Step 25

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

AUTODOC recommends:
Replacement: brake discs – VW PASSAT ALLTRACK (3G5). After applying the spray, wait a few minutes.
Step 26

Install the brake caliper bracket.
Step 27

Tighten the brake caliper bracket. Use a drive socket #21. Use a torque wrench. Tighten it to 175 Nm torque.
Step 28

Treat the brake caliper piston. Use a nylon cleaning brush. Use a brake cleaner.

Replacement: brake discs – VW PASSAT ALLTRACK (3G5). Tip from AUTODOC experts:
After applying the spray, wait a few minutes.
Step 29

Press in the brake caliper piston. Use brake caliper wind back tool.
Step 30

Install the brake pads.
Step 31

Install the brake caliper and fix it. Use HEX No.H7. Use a torque wrench. Tighten it to 30 Nm torque.
Step 32

Install the dust boot caps of the brake caliper guide pins.
Step 33

Install the brake caliper retaining spring. Use a crowbar.
Step 34

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 35

Clean the brake disk surface. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake discs – VW PASSAT ALLTRACK (3G5). After applying the spray, wait a few minutes.
Step 36

Install the wheel.

AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. VW PASSAT ALLTRACK (3G5)
Step 37

Screw in the wheel bolts. Use wheel impact socket #17.
Step 38

Lower the car and working in a cross order, tighten the wheel bolts. Use wheel impact socket #17. Use a torque wrench. Tighten it to 120 Nm torque.
Step 39

Remove the jacks and chocks.

Replacement: brake discs – VW PASSAT ALLTRACK (3G5). AUTODOC recommends:
Check the brake fluid level in the expansion tank and refill if necessary.
Step 40

Tighten the brake fluid reservoir cap.

AUTODOC recommends:
Without starting the engine, press the brake pedal several times until you feel significant resistance.
Step 41

Install the engine solenoid valve bracket. Use Torx T27. Use a ratchet wrench.

Step 42

Close the hood.

Was this manual helpful?

Please rate this manual on a scale from 1 to 5. If you have any questions, feel free to ask us.

How to change front brake pads on VW Passat Alltrack (3G5, CB5) – replacement guide

Free download PDF
1.57 MB
How to change rear wheel bearing on VW Passat Alltrack (3G5, CB5) – replacement guide

Free download PDF
1.76 MB
How to change front wheel bearing on VW Passat Alltrack (3G5, CB5) – replacement guide

Free download PDF
2.49 MB
How to change spark plugs on VW Passat Alltrack (3G5, CB5) – replacement guide

Free download PDF
1.2 MB
How to change rear windshield wipers on VW Passat B8 Alltrack (3G5, CB5) – replacement guide

Free download PDF
1.59 MB
How to change front windshield wipers on VW Passat Alltrack (3G5, CB5) – replacement guide

Free download PDF
737.28 KB

How to change front brake discs on VW Passat Saloon (3C2) – replacement guide

Free download PDF
2.19 MB
How to change rear brake discs on VW Passat Saloon (3C2) – replacement guide

Free download PDF
2.12 MB
How to change front brake discs on VW Passat Variant (3G5, CB5) – replacement guide

Free download PDF
2.19 MB
How to change rear brake discs on VW Passat CC (357) – replacement guide

Free download PDF
2.12 MB
How to change front brake discs on VW Passat CC (357) – replacement guide

Free download PDF
2.18 MB
How to change front brake discs on VW Passat Variant (365) – replacement guide

Free download PDF
2.18 MB

Your profile is your personal assistant.

It can track car expenses, keep a car log and replacement schedule, and save favourite materials, notes and documents

Install the AUTODOC CLUB app!

Your personal car expenses manager, maintenance tips, reminders about upcoming appointments and service intervals, DIY repair instructions – all this on your phone.

Scan

To download the app:

- scan the QR code
- download from App Store
- download from Google Play

Top 5 mistakes when working in the engine bay | AUTODOC tips

7K views

Published on: 04/08/2023
How to replace the suspension on a BMW E30 Turbo | SUPERCAR AUTODOC

1K views

Published on: 04/03/2021
5 Tips for New Drivers | AUTODOC tips

3K views

Published on: 31/01/2023
What to do if the ABS light comes on | AUTODOC tips

6K views

Published on: 11/03/2021