How to carry out replacement: Brake Discs 1.8 Passat 3a5
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Change Passat 3a5 1.8 Brake Discs yourself – manuals and video tutorials

How to change front brake discs on VW PASSAT Variant (3A5, 35I) – replacement guide

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When to replace the Brake Discs on your VW PASSAT
Recommended replacement interval for the part category Brake disc : 50000 km
Important!
This replacement procedure can be used for:
VW PASSAT Variant (3A5, 35I) 2.0 16V … 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

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Tools
Replacement: brake discs – VW PASSAT Variant (3A5, 35I). Tools you might need:
Wire brush
Nylon cleaning brush
WD-40 spray
Brake cleaner
Copper grease
Torque wrench
Torx bit T30
HEX bit No.H6
Wheel impact socket #17
Ratchet wrench
Brake caliper wind back tool
Crow bar
Wheel chock
Buy tools
Replacement: brake discs – VW PASSAT Variant (3A5, 35I). Tip from AUTODOC:
  • Replace the brake disks on the car VW PASSAT Variant (3A5, 35I) 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 Variant (3A5, 35I) – should be done with the engine switched off.
Carry out replacement in the following order:
  1. Step 1
    Open the bonnet. Unscrew the brake fluid reservoir cap.
    Step 2
    Secure the wheels with chocks.
    Step 3
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    Loosen the wheel mounting bolts. Use wheel impact socket #17.
  2. Step 4
    Raise the front of the car and secure on supports.
    Step 5
    How to replace VW PASSAT Variant (3A5, 35I) 1.8 1989 Brake Discs - step-by-step manuals and video guides
    Unscrew the wheel bolts.
    AUTODOC recommends:
    Warning! To avoid injury, hold the wheel while unscrewing the fastening bolts. VW PASSAT Variant (3A5, 35I)
  3. Step 6
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    Remove the wheel.
  4. Step 7
    Remove the dust boot caps of the brake caliper guide pins. Use a crowbar.
    Step 8
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    Clean the brake caliper fasteners. Use a wire brush. Use WD-40 spray.
  5. Step 9
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    Unscrew the brake caliper fastening. Use HEX No.H6. Use a ratchet wrench.
  6. Step 10
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    Spread the brake pads. Use a crowbar.
  7. Step 11
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    Remove the brake caliper.
    Replacement: brake discs – VW PASSAT Variant (3A5, 35I). Tip from AUTODOC experts:
    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.
  8. Step 12
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    Remove the brake pads.
  9. Step 13
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    Clean the brake disc fastener. Use a wire brush. Use WD-40 spray.
  10. Step 14
    VW PASSAT 1.8 Brake Discs replacement: online guides and video tutorials
    Unscrew the brake disc fastening. Use Torx T30. Use an impact screwdriver.
  11. Step 15
    Replacing Brake Discs on Passat 3a5 1988 1.8 by yourself
    Remove the brake disc.
  12. Step 16
    PASSAT Variant (3A5, 35I) 1.6 TD 1989 Brake Discs DIY replacement workshop manual
    Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
  13. Step 17
    How to change Brake Discs on VW PASSAT Variant (3A5, 35I) 1990 - tips and tricks
    Clean the brake caliper bracket of dirt and dust. Use a wire brush. Use a brake cleaner.
    AUTODOC recommends:
    Replacement: brake discs – VW PASSAT Variant (3A5, 35I). After applying the spray, wait a few minutes.
  14. Step 18
    Step-by-step recommendations for DIY replacement Passat 3a5 1991 1.6 TD Brake Discs
    Install the brake disc.
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