Rear
Component Notes And Information
NOTE:
^ During removal and installation procedures, refer to the component location illustration above and component notes below.
^ When removing self locking bolts, counter hold guide bolts using a suitable wrench
^ To prevent brake fluid spillage draw the brake fluid from the reservoir using a bleeder bottle that is used ONLY for brake fluid.
^ Illustration shows components for vehicles with 5-bolt wheels. Assembly and service are the same for vehicles with 4-bolt wheels.
WARNING:
^ Brake fluid is poisonous and must NEVER be removed by siphoning with your mouth.
CAUTION:
^ After servicing caliper, depress brake pedal firmly several times to seat the pads in their normal operating position.
^ Do not re-use fasteners that are 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. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins.
^ Always follow recommendations in these instructions, replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.
1 Stub axle
2 Splash shield
3 Dished spring-type washer
- Large contact surface faces splash shield
4 Bolt
- Tighten to: 60 Nm (44 ft lb)
5 Cover ring
- Installed position, refer to Fig. 1 below
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
7 Seal
8 Inner wheel bearing
9 Brake disc
- Thickness: 10 mm (0.394 inch)
- Wear limit: 8 mm (0.315 inch)
- When worn always replace discs on both sides
- Assembly sequence for previously run brake discs:
Brake caliper -26-
Brake pads -25-
Brake carrier -24-
10 Wheel bolt
- Tighten to: 110 Nm (81 ft lb)
11 Thrust washer
12 Nut
- Adjusting wheel bearing play, refer to Transmission and Drivetrain
- Secure with lock ring -28- and new cotter pin -29-
13 Grease cap
- Removing/Installing, refer to Transmission and Drivetrain
14 Rear axle beam
15 Socket head bolt
- Tighten to: 10 Nm (7 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, or equivalent
17 Brake hose bracket
18 Bolt
- Tighten to: 56 Nm (41 ft lb)
19 Guide pin
20 Protective cap
21 Self-locking bolt
- Always replace
- Tighten to: 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 on models produced from October 1992
- Always replace when replacing brake 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
25 Brake pads
- Thickness for Base suspension: 12 mm (0.472 inch)
- Thickness for Plus suspension: 14 mm (0.551 inch)
- Wear limit: 7 mm (0.276 inch) (includes backing plate)
- Always replace both pairs at the same time
- Removing and installing, refer to procedures below
26 Brake caliper
- Servicing, refer to Overhaul
- Revised brake caliper, refer to information below
- After servicing or replacing, adjust parking brake cable. Adjustments
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 until after the parking brake is adjusted.
27 Outer wheel bearing
28 Lock ring
29 Cotter pin
30 Spring clip
31 Parking brake cable
- Adjusting parking brake. Adjustments
Procedures
Fig. 1 Installation Position Of Ring Cover
- Drive on cover ring using tube VW 519.
Dimension -a- = 9.5 mm (0.374 inch)
Revised Brake Caliper
- From October, 1992 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.
Removal
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.
CAUTION:
^ Do not allow the caliper to hang by the brake hose. The unsupported weight can stretch and damage the hose.
^ Do not disconnect the brake hose from the caliper when removing brake pads.
- Remove brake pads.
- Clean brake caliper and brake carrier.
- Bonding surface for brake pads must be free of adhesive and grease residues.
Installation For Models Produced Up To September 1992
WARNING: Brake fluid is poisonous and must never be extracted by mouth through a hose.
CAUTION:
^ Extract part of the brake fluid from the brake fluid reservoir before pushing back the pistons.
^ Use the bleeder bottle or a plastic bottle, which is used only for brake fluid, for extracting the fluid.
^ If this is not done, particularly if the brake fluid has been topped off, brake fluid may flow out and cause damage.
^ After installing pads, refill reservoir only to the MAX mark
- Screw in piston by turning knurled wheel of reset and screw out tool 3272 clockwise.
- Insert retaining spring, if equipped, into brake caliper.
- Install brake pads.
- Pull protective foil off outer brake pad backing plate.
NOTE:
^ Mount tool 3272 so that the tool collar (left arrow) is seated against caliper.
^ If the piston is difficult to move, use a 13 mm 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 mechanism in the brake caliper will be destroyed
- Install brake caliper with new self-locking bolts.
- Connect parking brake cable to brake caliper.
- Depress brake pedal firmly several times, with vehicle stationary, to seat brake pads in their normal operating position.
- Check brake fluid level in reservoir and add fluid as necessary.
Installation For Models Produced From October 1992
- The illustration shows a brake caliper for a vehicle with the later type caliper (the assembly sequence is the same as noted above)