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 Saloon (3C2) 1.6 FSI, VW Passat Saloon (3C2) 2.0 FSI, VW Passat Saloon (3C2) 1.9 TDI, VW Passat Saloon (3C2) 2.0 TDI 16V, VW Passat Saloon (3C2) 2.0 TDI, VW Passat Saloon (3C2) 1.6, VW Passat Saloon (3C2) 2.0 TFSI, VW Passat Saloon (3C2) 3.2 FSI 4motion, VW Passat Saloon (3C2) 2.0 TDI 16V 4motion, VW Passat Saloon (3C2) 2.0 FSI 4motion, VW Passat Saloon (3C2) 2.0 TDI, VW Passat Saloon (3C2) 2.0 TDI 4motion, VW Passat Saloon (3C2) 3.6 R36 4motion, VW Passat Saloon (3C2) 2.0 TDI, VW Passat Saloon (3C2) 2.0 TDI, VW Passat Saloon (3C2) 1.4 TSI, VW Passat Saloon (3C2) 1.8 TSI, VW Passat Saloon (3C2) 2.0 TDI, VW Passat Saloon (3C2) 2.0 TDI, VW Passat Saloon (3C2) 2.0 FSI, VW Passat Saloon (3C2) 1.4 TSI EcoFuel, VW Passat Saloon (3C2) 2.0 TDI, VW Passat Saloon (3C2) 2.0 BlueTDI, VW Passat Saloon (3C2) 1.6 TDI, VW Passat Saloon (3C2) 2.0 TDI 4motion, VW Passat Saloon (3C2) 1.8 TSI 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 Saloon (3C2) and other VW models
Tools
Replacement: brake discs – VW PASSAT (3C2). List of the tools you'll need:
Wire brush
Nylon cleaning brush
WD-40 spray
Brake cleaner
Copper grease
Torque wrench
Combination spanner #13
Combination spanner #15
Drive socket # 13
XZN socket bit # 14
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
AUTODOC recommends:
  • Replace the brake disks on the car VW PASSAT (3C2) 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 (3C2) – should be done with the engine switched off.
Carry out replacement in the following order:
  1. Step 1
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    Connect the scan and service tool.
  2. Step 2
    Put the parking brake system into service mode.
    Step 3
    Open the hood.
    Step 4
    Clean the brake fluid reservoir cap. Use a brake cleaner.
    AUTODOC recommends:
    Replacement: brake discs – VW PASSAT (3C2). After applying the spray, wait a few minutes.
    Step 5
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    Unscrew the engine solenoid valve bracket. Use Torx T27. Use a ratchet wrench.
  3. Step 6
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    Unscrew the brake fluid reservoir cap.
  4. Step 7
    Secure the wheels with chocks.
    Step 8
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    Loosen the wheel mounting bolts. Use wheel impact socket #17.
  5. Step 9
    Raise the rear of the car and secure on supports.
    Step 10
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    Unscrew the wheel bolts.
    AUTODOC recommends:
    Warning! To avoid injury, hold the wheel while unscrewing the fastening bolts. VW PASSAT (3C2)
  6. Step 11
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    Remove the wheel.
  7. Step 12
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    Spread the brake pads. Use a crowbar.
  8. Step 13
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    Clean the brake caliper fasteners. Use a wire brush. Use WD-40 spray.
  9. Step 14
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    Unscrew the brake caliper fastening. Use a combination spanner #13. Use a combination spanner #15. Use a drive socket #13. Use a ratchet wrench.
  10. Step 15
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    Remove the brake caliper.
    Replacement: brake discs – VW PASSAT (3C2). 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.
  11. Step 16
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    Remove the brake pads.
  12. Step 17
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    Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
  13. Step 18
    How to change Brake Discs on VW Passat Saloon (3C2) 2005 - tips and tricks
    Unscrew the caliper bracket fastening. Use XZN #14. Use a tap wrench.
  14. Step 19
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    Remove the caliper bracket.
  15. Step 20
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    Clean the brake disc fastener. Use a wire brush. Use WD-40 spray.
  16. Step 21
    How to change Brake Discs on Passat B6 2005 - free PDF and video manuals
    Unscrew the brake disc fastening. Use Torx T30. Use an impact screwdriver.
  17. Step 22
    How to replace VW Passat Saloon (3C2) 1.9 TDI 2006 Brake Discs - step-by-step manuals and video guides
    Remove the brake disc. Use a rubber mallet.
  18. Step 23
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    Clean the hub. Use a wire brush.
  19. Step 24
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    Treat the contacting surface. Use copper grease.
  20. Step 25
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    Install the brake disc.
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DIY VW Passat Saloon (3C2) Brake Discs replacement - online guide
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