How to carry out replacement: Brake Discs 1.9 TDI Passat 3b5
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Change Passat 3b5 1.9 TDI Brake Discs yourself – manuals and video tutorials

How to change front brake discs on VW PASSAT Variant (3B5) – 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 (3B5) 1.6, VW PASSAT Variant (3B5) 1.8, VW PASSAT Variant (3B5) 1.8 T, VW PASSAT Variant (3B5) 2.3 VR5, VW PASSAT Variant (3B5) 2.8 V6, VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 2.8 V6 Syncro/4motion, VW PASSAT Variant (3B5) 1.8 Syncro/4motion, VW PASSAT Variant (3B5) 1.9 TDI Syncro/4motion, VW PASSAT Variant (3B5) 2.3 VR5 Syncro/4motion, VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 2.5 TDI, VW PASSAT Variant (3B5) 2.5 TDI Syncro/4motion, VW PASSAT Variant (3B5) 1.9 TDI 4motion, VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 2.0, VW PASSAT Variant (3B5) 2.0 4motion, VW PASSAT Variant (3B5) 1.8, VW PASSAT Variant (3B5) 2.8 V6, VW PASSAT Variant (3B5) 2.8 V6 … 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 Variant (3B5) and other VW models
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Tools
Replacement: brake discs – VW PASSAT Variant (3B5). Tools you might need:
Wire brush
WD-40 spray
Brake cleaner
Copper grease
Drive socket # 21
Combination spanner #13
Combination spanner #15
Wheel impact socket #17
Brake caliper wind back tool
Ratchet wrench
Torque wrench
Tap wrench
Crow bar
Wheel chock
Buy tools
Replacement: brake discs – VW PASSAT Variant (3B5). AUTODOC experts recommend:
  • Replace the brake disks on the car VW PASSAT Variant (3B5) 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 (3B5) – should be done with the engine switched off.
Carry out replacement in the following order:
  1. Step 1
    How to change Brake Discs on Passat 3b5 1997 - free PDF and video manuals
    Open the bonnet. Unscrew the brake fluid reservoir cap.
  2. Step 2
    How to replace VW PASSAT Variant (3B5) 1.9 TDI 1998 Brake Discs - step-by-step manuals and video guides
    Secure the wheels with chocks.
  3. Step 3
    Passat 3b5 1.8 T 1999 Brake Discs replacement: free workshop manuals
    Loosen the wheel mounting bolts. Use wheel impact socket #17.
  4. Step 4
    Raise the front of the car and secure on supports.
    Step 5
    Changing Brake Discs on VW PASSAT Variant (3B5) 1.6 2000 by yourself
    Unscrew the wheel bolts.
    Replacement: brake discs – VW PASSAT Variant (3B5). AUTODOC recommends:
    To avoid injury, hold up the wheel when unscrewing the bolts.
  5. Step 6
    How to remove VW PASSAT 1.9 TDI Syncro/4motion 2001 Brake Discs - online easy-to-follow instructions
    Remove the wheel.
  6. Step 7
    How to replace Brake Discs on VW PASSAT Variant (3B5) 1997: download PDF manuals and video instructions
    Clean the brake caliper fasteners. Use a wire brush. Use WD-40 spray.
  7. Step 8
    How hard is it to do yourself: Brake Discs replacement on Passat 3b5 1.9 TDI 4motion 1998 - download illustrated guide
    Unscrew the brake caliper fastening. Use a combination spanner #13. Use a combination spanner #15.
  8. Step 9
    Need to know how to renew Brake Discs on VW PASSAT 1999? This free workshop manual will help you to do it yourself
    Disconnect the brake pads wear sensor. Use a crowbar.
    Please note!
    Some cars are not equipped with the brake pad wear sensor.
  9. Step 10
    Changing of Brake Discs on Passat 3b5 2000 won't be an issue if you follow this illustrated step-by-step guide
    Spread the brake pads. Use a crowbar.
  10. Step 11
    VW PASSAT 1.9 TDI Brake Discs replacement: online guides and video tutorials
    Remove the brake caliper.
    Replacement: brake discs – VW PASSAT Variant (3B5). 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.
  11. Step 12
    Replacing Brake Discs on Passat 3b5 1997 1.9 TDI by yourself
    Remove the brake pads.
  12. Step 13
    PASSAT Variant (3B5) 1.9 TDI Syncro/4motion 1998 Brake Discs DIY replacement workshop manual
    Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
  13. Step 14
    How to change Brake Discs on VW PASSAT Variant (3B5) 1999 - tips and tricks
    Unscrew the caliper bracket fastening. Use a drive socket #21. Use a ratchet wrench. Use a tap wrench.
  14. Step 15
    Step-by-step recommendations for DIY replacement Passat 3b5 2000 1.9 TDI Syncro/4motion Brake Discs
    Remove the caliper bracket.
  15. Step 16
    DIY replacement of Brake Discs on VW PASSAT Variant (3B5) 1.8 2001 is not an issue anymore with our step-by-step tutorial
    Remove the retaining ring. Use a crowbar.
  16. Step 17
    How to change Brake Discs on Passat 3b5 1997 - free PDF and video manuals
    Remove the brake disc.
  17. Step 18
    How to replace VW PASSAT Variant (3B5) 1.9 TDI 1998 Brake Discs - step-by-step manuals and video guides
    Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
  18. Step 19
    Passat 3b5 1.8 T 1999 Brake Discs replacement: free workshop manuals
    Install the brake disc.
  19. Step 20
    Changing Brake Discs on VW PASSAT Variant (3B5) 1.6 2000 by yourself
    Install the retaining ring.
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