Rear disc brakes, servicing Page 1 / 17

46-27

Rear disc
brakes,
servicing
WARNING!

Do not re-use
fasteners that a
worn or
deformed in
normal use.
Some fasteners
are designed to
be used only
once, and are
unreliable and
may fail if used a
second time. Th
includes, but is
not limited to,
nuts, bolts,
washers, circlips
and cotter pins.
Always follow
recommendation
in this manual-
replace these
fasteners with
new parts where
indicated, and
any other time it
is deemed
necessary by
inspection.

Note:

Illustration shows
components for
vehicles with 5-bolt
wheels. Assembly
and service are the
same for vehicles
with 4-bolt wheels.

1 - Stub axle
Rear disc brakes, servicing Page 2 / 17

2 - Splash shiel
Rear disc brakes, servicing Page 3 / 17

46-28

3 - Dished
spring-
type
washer
Large
contact
surface
faces
splash
shield
4 - 60 Nm
(44 ft
lb)
5 - Cover
ring
Installed
position
Fig. 1
6 - ABS
wheel
speed
sensor
rotor
For
ABS
wheel
speed
sensor
To
drive
off,
insert
drift
through
wheel
bolt
holes
Drive
on
using
suitable
sleeve
Rear disc brakes, servicing Page 4 / 17

7 - Seal
8 - Inner
wheel
bearing
9 - Brake
disc
Thickness:
10 mm
(0.394 in.)
Wear
limit:
8 mm
(0.315
in.)
When
worn
always
replace
discs
on
both
sides
Assembly
sequence
for
previously
run brake
discs:
Brake
caliper
- 26 -
Brake
pads -
25 -
Brake
carrier
- 24 -
Rear disc brakes, servicing Page 5 / 17

46-29

10 - Wheel
bolt
110
Nm
(81 ft
lb)
11 - Thrust
washer
12 - Nut
Adjusting
wheel
bearing
play
Page 42-
21
Secure
with
lock
ring -
28 -
and
new
cotter
pin -
29 -
13 - Grease
cap
Removing
Page
42-28
Installing
Page
42-29
14 - Rear
axle
beam
15 - Socket
head
bolt

10
Nm (7
Rear disc brakes, servicing Page 6 / 17

ft lb)
16 - ABS
wheel
speed
sensor
-G44-/-
G46-
Before
installing
sensor,
clean
mounting
hole inner
surface
and coat
with
lubricating
paste,
Part No.
G 000
650
17 - Brake
hose
bracket
Rear disc brakes, servicing Page 7 / 17

46-30

18 - 56 Nm
(41 ft lb)
19 - Guide pin
20 - Protective
cap
21 - Self-
locking
bolt
Always
replace
35 Nm
(26 ft lb)
Hold
guide bolt
- 19 -
when
loosening
and
tightening
22 - Upper
pad
retaining
spring
Always
replace
when
replacing
brake
pads
23 - Lower
pad
retaining
spring
Introduced
from
10.92

Always
replace
when
replacing
brake
Rear disc brakes, servicing Page 8 / 17

pads
24 - Brake
carrier
Replacement
part comes
assembled
with guide
pins greased
With
guide
pins and
protective
caps
If guide
bolts or
protective
caps are
damaged,
install
repair kit
and use
grease
pack to
lubricate
guide
bolts
Rear disc brakes, servicing Page 9 / 17

46-31

25 - Brake
pads
Thickness
for Base
suspension:
12 mm
(0.472 in.)
Thickness
for Plus
suspension:
14 mm
(0.551 in.)
Wear
limit: 7
mm
(0.276
in.)
(includes
backing
plate)
Checking
thickness:
Repair
Manual,
Maintenance
Always
replace
both
pairs at
the
same
time
Removing
and
installing
Page
46-35
Rear disc brakes, servicing Page 10 / 17

46-32

26 - Brake
caliper
Servicing
Page
47-23
Revised
brake
caliper
Page
46-34
After
servicing
or
replacing,
adjust
parking
brake
cable
Page 46-
38

CAUTION!

Do not
disconnect
the brake
hose from
the caliper
when
replacing
brake pads.
Do not allow
the caliper
to hang by
the brake
hose. The
unsupported
weight can
stretch and
damage the
hose.

Do not
depress the
brake pedal
Rear disc brakes, servicing Page 11 / 17

until after
parking
brake is
adjusted
Page 46-38 .
27 - Outer
wheel
bearing
28 - Lock
ring
29 - Cotter
pin
30 - Spring
clip
31 - Parking
brake
cable
Adjusting
parking
brake
Page 46-
38
Rear disc brakes, servicing Page 12 / 17

46-33

Fig. 1 Installation position of

ring cover
- Drive on cover ring using tube
VW 519.
Dimension -a- = 9.5 mm (0.374
in.)
Rear disc brakes, servicing Page 13 / 17

46-34

Revised brake caliper

From 10.92 a revised brake caliper
has been installed on the rear axle.

The brake caliper can be identified

by the bolted-on parking brake cable
securing point -A-. The previous
version of the brake caliper has the
parking brake securing point cast
directly to the caliper.
Rear disc brakes, servicing Page 14 / 17

46-35

Rear disc brake pads,

removing and installing

Removing

CAUTION!

If the brake pads are to be reused,

mark their installed positions
before removal. Re-install in their
original positions to avoid uneven
braking.

- Remove wheels.

- Disconnect parking brake cable

from brake caliper.

- Remove brake caliper and brake

pads.

CAUTION!

Do not allow caliper to hang by

brake hose. The unsupported
weight can stretch and damage
the hose.
Do not disconnect the brake
hose from the caliper when
removing brake pads.
- Clean brake caliper and brake
carrier.
Brake pad bonding surfaces must
be free of adhesive and grease
residue.
Rear disc brakes, servicing Page 15 / 17

46-36

Installing

WARNING!

Brake fluid is poisonous and must never

extracted by mouth through a hose.

CAUTION!

Extract part of the brake fluid from the

fluid reservoir before pushing back the
pistons.

Use the bleeder bottle or a plastic bott

which is used only for brake fluid, for
extracting the fluid.

Otherwise, especially if brake fluid has

topped off, brake fluid may flow out an
cause damage.

After installing pads, refill reservoir on

the MAX mark

- Screw in piston by turning knurled wheel

and screw out tool 3272 clockwise.
- Insert retaining spring, if equipped, into b
caliper.
- Install brake pads.
- Pull protective foil off outer brake pad bac
plate.
Rear disc brakes, servicing Page 16 / 17

46-37

Note:

Mount tool 3272 with collar (left arrow) s

against caliper

If the piston is difficult to move, use a 13

open-end wrench on tool flats (arrow -A-

CAUTION!

If the piston is pushed back with a piston

resetting tool, or by operating the brake
pedal, the automatic adjustment mechan
in the brake caliper will be destroyed.

- Install brake caliper with new self-locking

- Connect parking brake cable to brake cal
- Depress brake pedal firmly several times
vehicle stationary, to seat brake pads in t
normal operating position.
- Check brake fluid level in reservoir and a
as necessary.

The illustration shows a brake caliper for a v

from 10.92 (the assembly sequence is the s
Rear disc brakes, servicing Page 17 / 17

46-38

Parking brake, adjusting

(Vehicles with rear disc brakes)

Note:

Because of the automatic

adjustment function of the rear
brakes, readjusting the parking
brake is usually not necessary.
Readjust only if the parking brake
cables, brake calipers, or brake pads
and discs have been replaced.

- Remove hand grip and center

console to access adjusting nuts
(arrows).
- Release parking brake.

- Tighten adjusting nut until lever

lifts off of stop on caliper.
Gap (arrow) between lever
and stop should be 1.0-3.0
mm (0.04-0.12 in.) and same
on both sides
A = Up to m.y. 1995 (S)
B = From m.y. 1996 (T)
1 - Feeler gauge
- Pull up and then release parking
brake three times.
- Check that both wheels turn
freely.