I hate plastic on cars. I change the brakes on my 2006 passat. 50% of the caliper assembly is plastic. the flange where the plastic is screwed to the metal caliper assembly is cracked and i need a new one, but i dont know what this plastic part is. Hint, is has wiring attached. PLease help.
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Remove the wheels Stick a punch or something sturdy in a rotor cooling hole so it jams against the caliper. Loosen the 8 nuts that can be accessed through the 8 holes in the hub flange. Remove the calipers from the knuckles and hang them from something other than the brake hose. Remove the previously loosened 8 rotor nuts. Tap the rotor with a hammer and it should fall off.
Loosen the lug nuts Raise the vehicle up Place safety stand under the car Remove the Tire 6mm Hex to take out the center bolts Remove the Caliper compress the piston of the Caliper Inspect the Rotor and determine if they need to be turned or replaced reintall in reverse order
Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.
Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper.
Remove the rotor retaining push nuts from the wheel studs, if applicable.
It may be necessary to strike the end of the hub or the rotor with a deadblow hammer to separate the rotor from the hub.
Remove the rotor by slowly fuming the rotor while pulling the rotor away from the axle.
Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J42450 hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and brake pulsation.
Use the J42450-A to clean all rust and contaminants from the mating surface of the hub flange.
Use the J41013 to clean all rust and contaminants from the inside diameter of the hub section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange.
Install the rotor by slowly fuming the rotor while pushing the rotor towards the axle.
Install the caliper and the bracket as an assembly to the vehicle.
Perform the following procedure before installing the caliper bracket mounting bolts.
Remove all traces of the original adhesive patch.
Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.
Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.
Notice: Refer to Fastener Notice in Service Precautions.
Install the caliper bracket mounting bolts.
For the 15 Series, tighten the brake caliper bracket mounting bolts to 175 Nm (129 ft. lbs.).
For the 25 series, tighten the brake caliper bracket mounting bolts to 300 Nm (221 ft. lbs.).
Install the tire and wheel assembly.
Lower the vehicle.
With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
Slowly release the brake pedal.
Wait 15 seconds, then repeat steps 9-10 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
Fill the master cylinder reservoir to the proper level with clean brake fluid.
Hello, to change the headlight on your passat, follow this steps:
1. Pull off the air intake cover, and remove the intake mounting bolt and set the intake hose aside,(passenger side only).
2. Twist off the protective cover from the back of the headlight assembly. Press the tab to pull off the electrical connector.
3. Turn the bulb socket counter clockwise to unlatch, and then slip it away from the assembly.
4. Turn the old bulb counter clockwise to release from the socket .Install the new bulb by turning it clockwise. Hold the plastic base of the new bulb when installing . Touching the glass can cause it to prematurely fail.
5. Insert the module and turn it clockwise to lock it in the assembly. Reattach the electrical connector and twist the protective rubber cover unto the back of the assembly .
6. Reattach the intake hose (passenger side only) and tighten the bolt. Snap the plastic intake cover back on.
Removal & Installation
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.
The brake rotor can be removed without separating the caliper from the mounting bracket.
Release the parking brake.
Remove 2/3 of the brake fluid from the master cylinder.
Raise and support the vehicle.
Remove the tire and wheel assembly.
Remove the caliper and mounting bracket as an assembly.
Hang the caliper and mounting bracket assembly from the suspension using mechanics wire.
Remove the rotor. Slowly turn the rotor while pulling the rotor away from the axle. (15 series).
Remove the rotor. Slowly turn the rotor while pulling the rotor away from the axle. (25 series).
If the rotor is stuck to the hub, try using a slide hammer to free it.
Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral run-out (LRO) of the brake rotor, which could lead to brake pulsation.
Thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.
Thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.
Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
Install the rotor. Slowly turn the rotor while pushing the rotor towards the axle. (15 series).
Install the rotor. Slowly turn the rotor while pushing the rotor towards the axle. (25 series).
Install the caliper and the mounting bracket as an assembly.
an 06 passat has special rear calipers that have to be taken in by a scan tool if you try to turn them in you will damage parking brake motor the brakes also need reset after installation by scan tool or there will be codes in parking brake circuit but the fronts are normal except for sensors on the inboard pads but i beleive at the dealer its around 800 for rotors and pads all the way round the grille im not sure of maybe 150-200 total
this is for 2003 7.5 inch ring gear axle.
SECTION 205-02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring Gear 2003 Mustang Workshop Manual
IN-VEHICLE REPAIR Drive Pinion Flange and Drive Pinion Seal
Special Tool(s) 2-Jaw Puller
205-D072 (D97L-4221-A) or equivalent Holding Fixture, Drive Pinion Flange
205-126 (T78P-4851-A) Installer, Drive Pinion Flange
205-002 (TOOL-4858-E) or equivalent
Raise and support the vehicle.
Remove the rear wheel and tire assemblies.
CAUTION: Remove the rear brake calipers to prevent drag during the drive pinion bearing preload adjustment. CAUTION: Do not allow the calipers to hang from the brake hoses.
Remove the rear brake caliper and support bracket from the knuckle as an assembly. Wire the caliper and support bracket assembly out of the way.
CAUTION: Index-mark the driveshaft flange and pinion flange (4851) to maintain initial balance during installation. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown, with a suitable tool, to disconnect the yoke from the flange.
Disconnect and position the driveshaft out of the way.
Install an Nm (inch/pound) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions.
CAUTION: After removing the nut, discard it. Use a new nut for installation.
Use the special tool to hold the pinion flange while removing the nut.
Index-mark the pinion flange and drive pinion gear stem to maintain initial balance during installation.
Using the special tool, remove the pinion flange.
Inspect the pinion flange seal journal for rust, nicks, and scratches prior to installing the flange. Polish the seal journal with fine crocus cloth, if necessary.
Lubricate the pinion flange splines.
Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
NOTE: Disregard the index marks if installing a new pinion flange.
Position the pinion flange.
Using the special tools, install the pinion flange.
CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer (4662) and nut. CAUTION: Remove the special tool while taking preload readings with the Nm (inch/pound) torque wrench.
Tighten the nut to set the preload.
Rotate the drive pinion occasionally to make sure the differential pinion bearings (4630) (4621) seat correctly. Take frequent differential pinion bearing torque preload readings by rotating the drive pinion with a Nm (inch/pound) torque wrench.
If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the nut to the original reading as recorded.
Refer to the torque specification for used differential pinion bearings in the Specifications portion of this section.
CAUTION: Align the index marks. CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 to the threads of the original bolts. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.
Connect the driveshaft. .
If you can't see diagrams(sometimes happens) let me know and I will get them to you
Raise and support the vehicle. Remove the rear wheels.
If equipped, disconnect the brake pad wear sensor from the harness.
Counterhold the lower sliding pin using a thin open-end wrench and remove the caliper-to-sliding pin hex bolt.
Pivot the caliper upward or if necessary remove the upper caliper-to-sliding pin hex bolt.
a brake caliper retraction tool, select the appropriate sized piston
press arbor and install the tool onto the brake caliper. Following the
tool manufacturer's recommendations, use the tool to rotate the caliper
piston clockwise as it is pressed into the brake caliper housing, until
it is fully retracted.
Use a thin open-end wrench to . . .. . . support the caliper sliding pin when removing the caliper mounting boltUse a disc brake caliper piston retracting tool that will rotate the caliper piston as it is pressed into the caliperThe rear caliper piston is slotted to allow a retracting tool to rotate the piston when replacing the brake padsTo install:
the brake caliper and all sliding surfaces. With the caliper piston
pressed fully back into the caliper housing, check for leaking fluid
and damaged dust boots.
If equipped, install a new brake pad
wear sensor in the pad if the plastic part has been worn through on the
old sensor. New sensors are not required unless the wire inside the
plastic part has been exposed.
Lubricate the slider bolts with approved brake grease.
the brake pads onto the bracket assembly, and then carefully lower the
caliper over the caliper mount. Check and make sure that the pad
springs are correctly seated.
Replace all removed caliper-to-sliding pin bolts and torque to:
1990-97 Passat models: 25 ft. lbs. (35 Nm)
1998-00 Passat models: 22 ft. lbs. (30 Nm)
equipped, connect the brake wear sensor wire to the harness. Check for
a good connection as most problems with the sensor circuit are caused
by faulty connections. Check that the wire is held by the loop in the
dust cover and the connector is held at the clips.
wheels and hand tighten the lug bolts. Lower the vehicle carefully
until the tires begin to contact the surface and torque the lug bolts
to specification in a crisscross pattern to: