Brake caliper FN 44, servicing
Rear brakes, FN44 brake caliper, servicing
Note:
^ After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position.
^ To siphon off brake fluid from the brake fluid reservoir, use the brake filler and bleeder unit VAS5234.
^ Before removing a brake caliper or disconnecting a brake hose, the brake pedal loading device V.A.G. 1869/2 should be installed (to relieve pressure).
1 - Brake disc/brake drum
^ Ventilated brake disc: diameter 314 mm
^ Brake disc thickness: 22 mm
^ Wear limit: 18 mm
^ Brake drum: diameter 185 mm
^ Wear limit 186 mm
^ Always replace both sides Remove brake caliper and carrier prior to removing
2 - Installed bolt, 20 Nm
^ Brake disc to wheel bearing housing
3 - Carrier
^ Bolt to wheel bearing housing
4 - Hex head bolt, 180 Nm
5 - Brake pads
^ Thickness 13 mm not including backing plate
^ Wear limit: 2 mm not including backing plate
^ With wear indicator
^ When wear limit is reached (limit: approximately 4 mm) warning lamp lights up on dash panel
^ Always replace both sides
6 - Retaining spring
7 - Brake caliper
^ Do not disconnect brake lines to replace brake pads or brake discs
8 - Retainer for brake pad wear indicator wiring
9 - Bolt, 10 Nm
10 - Guide pins, 30 Nm
11 - Cap
12 - Hex socket head bolt, 8 Nm
13 - Bracket
14 - Brake line with banjo fitting and hollow bolt, 38 Nm
^ Attach to brake caliper
^ Do not disconnect brake lines to replace brake pads or brake discs
15 - Pin
16 - Spring
17 - Spring
^ Installation location: at the adjusting nut
^ Differences between tensioning spring
^ Higher number of spring coils
^ Easy to bend by hand
18 - Spring
^ Installation location: at the expander
^ Differences between tensioning spring
^ Smaller number of spring coils
^ Hard to bend by hand
19 - Brake shoe
^ Minimum lining thickness 1 mm
^ Checking thickness
20 - Expander
21 - Adjustment nut
22 - Carrier
23 - Rear brake cable
Brake caliper, removing and installing
Special tools, testers and auxiliary items required
^ Torque wrench V.A.G 1331
^ Brake pedal depressor V.A.G 1869/2
Removing
This work sequence is only necessary for replacing, or for after servicing, brake caliper.
- Remove wheels.
- Press retaining spring in - direction of arrow A - until it can be pressed out of bore in - direction of arrow B -.
- Turn retaining spring - 1 - clockwise - arrow - until it can be removed from upper bore.
- Separate connector - 1 - for brake pad wear indicator.
- Remove wire for brake pad wear indicator from retainer - 2 - on caliper.
- Remove lower connector - 3 - of the brake wear indicator and wheel speed sensor - 4 - from retainer on brake caliper.
- Press bleeder bottle hose onto bleeder valve of brake caliper and then open bleeder valve.
- Install brake pedal loading device V.A.G 1869/2.
- Close bleeder valve and remove bleeder bottle.
- Disconnect brake line.
- Remove caps - arrows -.
- Remove both guide pins - arrows - from brake caliper.
- Remove brake caliper from carrier.
- Remove brake pads from brake caliper.
Installing
^ The piston is pushed back.
^ The outer brake pad sits on carrier.
- Set inner brake pad with retaining springs into brake caliper (piston).
Note:
^ The inner (piston side) brake pads are directional and specific to each side of the vehicle. They are designated by markings that show the direction of travel.
Directional brake pads
Note:
^ In installed position, the arrow - A - on the backing plate of the brake pad points down (in rotation direction of brake disc).
- Attach brake caliper to carrier by fastening guide pins - arrows -.
- Install both caps.
- Connect brake line to brake caliper.
- Remove brake pedal loading device V.A.G 1869/2.
- Press wheel speed sensor wiring - 4 - into retainer on brake caliper.
- Reconnect connectors - 3 - and - 1 - for brake wear indicator in retainer on brake caliper.
- Secure brake wear indicator wiring in retainer - 2 - on brake caliper.
- Install retaining spring into upper bore - arrow - and turn down - direction of arrow -.
- Set retaining spring on bottom of carrier.
- First press retaining spring in - direction of arrow A -, then at the same time into bore of brake caliper - direction of arrow B -.
- Bleed brake system.
- Install wheels.
Tightening torque specification for wheel bolts.
Note:
^ After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position.
^ Check brake fluid level.
Tightening torques:
