Important!
This replacement procedure can be used for:
VW PASSAT (3B3) 1.8 T 20V, VW PASSAT Variant (3B6) 1.8 T 20V

The steps may slightly vary depending on the car design.

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

Required tools:
Required tools:
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
AUTODOC recommends:
  • 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.
Carry out replacement in the following order:
  1. How to change Brake Calipers on Passat 3B6 2000 - free PDF and video manuals
    Step 1
    Open the bonnet.Unscrew the brake fluid reservoir cap.
  2. How to replace VW PASSAT Variant (3B6) 1.9 TDI 2001 Brake Calipers - step-by-step manuals and video guides
    Step 2
    Secure the wheels with chocks.
  3. Passat 3B6 1.8 T 20V 2002 Brake Calipers replacement: free workshop manuals
    Step 3
    Loosen the wheel mounting bolts.Use wheel impact socket #17.
    Step 4
    Raise the rear of the car and secure on supports.
  4. Changing Brake Calipers on VW PASSAT Variant (3B6) 2.0 2003 by yourself
    Step 5
    Unscrew the wheel bolts.
    AUTODOC recommends:
    To avoid injury, hold up the wheel when unscrewing the bolts.
  5. How to remove VW PASSAT 1.6 2004 Brake Calipers - online easy-to-follow instructions
    Step 6
    Remove the wheel.
  6. How to replace Brake Calipers on VW PASSAT Variant (3B6) 2005: download PDF manuals and video instructions
    Step 7
    Disconnect the parking brake cable from the caliper.Use a flat screwdriver.
  7. How hard is it to do yourself: Brake Calipers replacement on Passat 3B6 2.0 TDI 2000 - download illustrated guide
    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.
  8. Need to know how to renew Brake Calipers on VW PASSAT ? This free workshop manual will help you to do it yourself
    Step 11
    Unscrew the brake caliper fasteningUse a combination spanner #15.Use a drive socket #13.Use a ratchet wrench.
  9. Changing of Brake Calipers on Passat 3B6 2002 won't be an issue if you follow this illustrated step-by-step guide
    Step 12
    Remove the brake caliper.Use a flat screwdriver.
    AUTODOC recommends:
    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.
  10. VW PASSAT 1.9 TDI Brake Calipers replacement: online guides and video tutorials
    Step 13
    Unscrew the brake hose from the brake caliper.Use a combination spanner #13.
  11. Replacing Brake Calipers on Passat 3B6 2004 1.9 TDI by yourself
    Step 14
    Remove the brake pads.
    AUTODOC recommends:
    Immediately plug the brake line open end to prevent fluid leakage and ingress of dirt into the hydraulic system.
  12. PASSAT Variant (3B6) 1.6 2005 Brake Calipers DIY replacement workshop manual
    Step 15
    Install the brake pads.
    Step 16
    Install and fix the brake hose into a new caliper.Use a combination spanner #13.
  13. How to change Brake Calipers on VW PASSAT Variant (3B6) 2000 - tips and tricks
    Step 17
    Install the brake caliper and fix it.
  14. Step-by-step recommendations for DIY replacement Passat 3B6 2001 1.6 Brake Calipers
    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.
  15. DIY replacement of Brake Calipers on VW PASSAT Variant (3B6) 1.9 TDI 4motion 2002 is not an issue anymore with our step-by-step tutorial
    Step 19
    Install the parking brake cable into the brake caliper bracket.Use a flat screwdriver.
  16. How to change Brake Calipers on Passat 3B6 2000 - free PDF and video manuals
    Step 20
    Secure the parking brake cable with the retaining clip.Use a flat screwdriver.
  17. How to replace VW PASSAT Variant (3B6) 1.9 TDI 2001 Brake Calipers - step-by-step manuals and video guides
    Step 21
    Undo the brake bleeder screw.Use a flare nut spanner #10.
  18. Passat 3B6 1.8 T 20V 2002 Brake Calipers replacement: free workshop manuals
    Step 22
    Bleed the brake caliper system.Without starting the engine, press the brake pedal several times until you feel significant resistance.
  19. Changing Brake Calipers on VW PASSAT Variant (3B6) 2.0 2003 by yourself
    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 25 Nm torque.
    AUTODOC recommends:
    Make sure to set the protection cap on the bleeder valve.
  20. How to remove VW PASSAT 1.6 2004 Brake Calipers - online easy-to-follow instructions
    Step 25
    Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
  21. How to replace Brake Calipers on VW PASSAT Variant (3B6) 2005: download PDF manuals and video instructions
    Step 26
    Clean the brake disk surface.Use a brake cleaner.
    AUTODOC recommends:
    After applying the spray, wait a few minutes.
  22. How hard is it to do yourself: Brake Calipers replacement on Passat 3B6 2.0 TDI 2000 - download illustrated guide
    Step 27
    Install the wheel.
    AUTODOC recommends:
    To avoid injury, hold up the wheel when screwing in the fastening bolts.
  23. Need to know how to renew Brake Calipers on VW PASSAT ? This free workshop manual will help you to do it yourself
    Step 28
    Screw in the wheel bolts.Use wheel impact socket #17.
  24. Changing of Brake Calipers on Passat 3B6 2002 won't be an issue if you follow this illustrated step-by-step guide
    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.
  25. VW PASSAT 1.9 TDI Brake Calipers replacement: online guides and video tutorials
    Step 30
    Remove the jacks and chocks.
    AUTODOC recommends:
    Check the brake fluid level in the expansion tank and refill if necessary.
  26. Replacing Brake Calipers on Passat 3B6 2004 1.9 TDI by yourself
    Step 31
    Tighten the brake fluid reservoir cap. Close the hood.
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