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

Important!

This replacement procedure can be used for:
VW PASSAT (3B2) 1.6, VW PASSAT (3B2) 1.8, VW PASSAT (3B2) 2.3 VR5, VW PASSAT (3B2) 1.9 TDI, VW PASSAT (3B2) 1.9 TDI, VW PASSAT (3B2) 1.8 Syncro/4motion, VW PASSAT (3B2) 1.9 TDI 4motion, VW PASSAT (3B2) 1.8, VW PASSAT (3B2) 2.8 V6, VW PASSAT Variant (3B5) 1.6, VW PASSAT Variant (3B5) 1.8, VW PASSAT Variant (3B5) 2.3 VR5, VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 1.8 Syncro/4motion, VW PASSAT Variant (3B5) 1.8, VW PASSAT Variant (3B5) 2.8 V6 … View more

The steps may slightly vary depending on the car design.

How to change a rear brake caliper on VW PASSAT B5+ TUTORIAL | AUTODOC

Alternative products

Brake caliper

Replacement: brake caliper – VW Passat B5 Variant. List of the tools you'll need:

                      Brake cleaner 
                    
                      Copper grease 
                    
                      Flare nut spanner #10
                    
                      Combination spanner #13
                    
                      Combination spanner #15
                    
                      Drive socket # 13 
                    
                      Wheel impact socket #17
                    
                      Ratchet wrench
                    
                      Torque wrench
                    
                      Flat Screwdriver
                    
                      Pliers 
                    
                      Wheel chock

Buy tools

Replacement: brake caliper – VW Passat B5 Variant. AUTODOC experts recommend:

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. Recommended sequence of 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 rear of the car and secure on supports.
Step 5

Unscrew the wheel bolts.

AUTODOC recommends:
Warning! To avoid injury, hold the wheel while unscrewing the fastening bolts. VW Passat B5 Variant
Step 6

Remove the wheel.
Step 7

Disconnect the parking brake cable from the caliper. Use a flat screwdriver.
Step 8

Remove the retaining clip of the parking brake cable. Use pliers.

Step 9

Release the parking brake cable. Use a flat screwdriver.

Step 10

Spread the brake pads. Use a flat screwdriver.
Step 11

Unscrew the brake caliper fastening. Use a combination spanner #15. Use a drive socket #13. Use a ratchet wrench.
Step 12

Remove the brake caliper. Use a flat screwdriver.

Replacement: brake caliper – VW Passat B5 Variant. 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. 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.If no new guide pins were supplied in a kit with the new brake calipers, use the old pins.
Step 13

Unscrew the brake hose from the brake caliper. Use a combination spanner #13.
Step 14

Remove the brake pads.

Replacement: brake caliper – VW Passat B5 Variant. AUTODOC recommends:
Immediately plug the brake line open end to prevent fluid leakage and ingress of dirt into the hydraulic system.
Step 15

Install the brake pads.

Step 16

Install and fix the brake hose into a new caliper. Use a combination spanner #13.
Step 17

Install the brake caliper and fix it.
Step 18

Tighten the brake caliper fasteners. Use a combination spanner #15. Use a drive socket #13. Use a torque wrench. Tighten it to 35 Nm torque.
Step 19

Install the parking brake cable into the brake caliper bracket. Use a flat screwdriver.
Step 20

Secure the parking brake cable with the retaining clip. Use a flat screwdriver.
Step 21

Undo the brake bleeder screw. Use a flare nut spanner #10.
Step 22

Bleed the brake caliper system. Without starting the engine, press the brake pedal several times until you feel significant resistance.
Step 23

Tighten the brake bleeder screw. Use a flare nut spanner #10.

Step 24

Tighten the brake caliper bleed screw. Use a flare nut spanner #10. Use a torque wrench. Tighten it to 10 Nm torque.

Replacement: brake caliper – VW Passat B5 Variant. Tip from AUTODOC:
Make sure to set the protection cap on the bleeder valve.
Step 25

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 26

Clean the brake disk surface. Use a brake cleaner.

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

Install the wheel.

Replacement: brake caliper – VW Passat B5 Variant. Tip:
To avoid injury, hold up the wheel when screwing in the fastening bolts.
Step 28

Screw in the wheel bolts. Use wheel impact socket #17.
Step 29

Lower the car and working in a cross order, tighten the wheel bolts. Use a torque wrench. Tighten it to 120 Nm torque.
Step 30

Remove the jacks and chocks.

Replacement: brake caliper – VW Passat B5 Variant. Tip from AUTODOC experts:
Check the brake fluid level in the expansion tank and refill if necessary.
Step 31

Tighten the brake fluid reservoir cap. Close the hood.

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