Question about 2006 Volkswagen Passat

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2006 passat caliper assembly

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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  • Anonymous Mar 30, 2014

    The plastic worm gear is encased in a a plastic housing and is being operated by a metal gear attached to the motor

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  • 94 Answers

Brake pad sensor if it has one wire or if it has more wires then its an abs sensor but my guess is its the electronic brake pad sensor

Posted on Mar 09, 2009

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1 Answer

How do you change the brake pads on a 2006 passat


Front Pads

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

NOTE: PUMP BRAKES BEFORE DRIVING

May 26, 2011 | Volkswagen Passat Cars & Trucks

1 Answer

How do I remove the rear rotors on a 2002 Yukon Denali


  1. Release the park brake.
  2. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
  3. Remove the tire and wheel assembly.
  4. Mark the relationship of the rotor to the hub.
  5. Remove the brake caliper bracket mounting bolts.
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.

  1. 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.
  2. Remove the rotor retaining push nuts from the wheel studs, if applicable.
  3. 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.
  4. Remove the rotor by slowly fuming the rotor while pulling the rotor away from the axle.
Installation Procedure

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.


  1. Use the J42450-A to clean all rust and contaminants from the mating surface of the hub flange.
  2. 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.
  3. Install the rotor by slowly fuming the rotor while pushing the rotor towards the axle.
  4. Install the caliper and the bracket as an assembly to the vehicle.
  5. 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.

  1. 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.).
  1. Install the tire and wheel assembly.
  2. Lower the vehicle.
  3. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  4. Slowly release the brake pedal.
  5. 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.
  6. Fill the master cylinder reservoir to the proper level with clean brake fluid.

Apr 19, 2011 | 2002 GMC Yukon Denali

1 Answer

How to replace rear wheel bearing on 2003 hyandia sonata


Hub & Bearing Removal & Installation To Remove:
Hub bearing assembly (Typical) hyundai-08-00-6029.gif

  1. Release parking brake.
  2. Remove rear wheel assembly.
  3. Remove rear wheel speed sensor from carrier.
  4. Dismount brake caliper and support with mechanic's wire.
  5. Remove brake disc.
  6. Remove 4 axle hub mounting bolts. Special tool 09432-11000 (Typical) hyundai-08-00-6021.gif

  7. Using tool 09432-11000 (or suitable gear puller), remove tone wheel.
  8. Remove carrier.
  9. Remove stakes and remove flange nut.
  10. Support bearing outer race flange and press rear axle hub out.
  11. Using tool 09432-11000 (or suitable puller), remove inner race from axle hub.
To Install:
Hub bearing assembly (Typical) hyundai-08-00-6029.gif

  1. Apply thin coat of grease to bearing contact surface and hub.
  2. Using and appropriate tool, press bearing into hub. CAUTION
    Do not press against outer race of wheel bearing.
  3. Install flange nut and stake nut until it meets concave portion of spindle.
  4. Install carrier.
  5. Use an appropriate tool to press tone wheel.
  6. Install hub/bearing assembly with rounded portion of outer race facing up.
  7. Install 4 hub/bearing assembly bolts and rotate hub to seat bearing.
  8. Measure wheel bearing starting torque with a spring balance or equivalent device.
    • Starting torque should measure 15.9 in lb (1.8 Nm) or less
  9. Install brake disc.
  10. Mount brake caliper.
  11. Install rear wheel speed sensor to carrier.
  12. Install rear wheel assembly.
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Oct 28, 2010 | 2001 Hyundai Sonata

1 Answer

How to take back rotors off a 1994 honda civic.


PATH: Brakes > Front Disc Brakes > Brake Disc (Rotor) > Removal & Installation Removal & Installation
  1. Raise and support the front of the vehicle on jackstands. Remove the front wheels.
  2. Remove the caliper assembly; do not let the caliper assembly hang by the brake hose, instead support it with a piece of wire looped around the front spring or control arm.
  3. Remove the retaining screw from the brake rotor and remove the rotor from the hub.

An impact driver, No. 3 phillips screwdriver bit, and a hammer may be needed to remove the retaining screw. It is fairly easy to destroy the screw slots using an ordinary phillips screwdriver to remove the tightly driven screw (see photo).

  1. To install the disc, replace the disc on the hub, screw in the retaining screw and replace the caliper assembly.
edc2fe7.gif
PATH: Brakes > Rear Disc Brakes > Brake Disc (Rotor) > Removal & Installation Removal & Installation
  1. Raise and safely support the vehicle.
  2. Remove the wheel and tire assembly.
  3. Disconnect the caliper from the caliper bracket. Support the caliper out of the way with a length of wire. Do not allow the caliper to hang from the brake hose.
  4. Remove the caliper bracket.
  5. Remove the two 6mm screws and the brake disc. If the brake disc is difficult to remove, install two 8mm bolts into the threaded holes and tighten them evenly to prevent cocking the rotor.
  6. Install the rotor in position. Install the two 6mm retaining screws.
  7. Install the brake caliper. Install the tire and wheel assembly.

PATH: Brakes > Rear Disc Brakes > Brake Disc (Rotor) > Removal & Installation Removal & Installation
  1. Raise and safely support the vehicle.
  2. Remove the wheel and tire assembly.
  3. Disconnect the caliper from the caliper bracket. Support the caliper out of the way with a length of wire. Do not allow the caliper to hang from the brake hose.
  4. Remove the caliper bracket.
  5. Remove the two 6mm screws and the brake disc. If the brake disc is difficult to remove, install two 8mm bolts into the threaded holes and tighten them evenly to prevent cocking the rotor.
  6. Install the rotor in position. Install the two 6mm retaining screws.
  7. Install the brake caliper. Install the tire and wheel assembly.

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Sep 15, 2010 | 1994 Honda Civic

1 Answer

How to change rear brake rotors 2004 gmc savana


Removal & Installation CAUTION 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.
  1. Release the parking brake.
  2. Remove 2/3 of the brake fluid from the master cylinder.
  3. Raise and support the vehicle.
  4. Remove the tire and wheel assembly.
  5. Remove the caliper and mounting bracket as an assembly.
  6. Hang the caliper and mounting bracket assembly from the suspension using mechanics wire.
  7. Remove the rotor. Slowly turn the rotor while pulling the rotor away from the axle. (15 series).
  8. Remove the rotor. Slowly turn the rotor while pulling the rotor away from the axle. (25 series).
    NOTE If the rotor is stuck to the hub, try using a slide hammer to free it.

To install:
WARNING 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.

  1. Thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.
  2. Thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.
  3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
  4. Install the rotor. Slowly turn the rotor while pushing the rotor towards the axle. (15 series).
  5. Install the rotor. Slowly turn the rotor while pushing the rotor towards the axle. (25 series).
  6. Install the caliper and the mounting bracket as an assembly.
  7. Install the tire and wheel assembly.
  8. Lower the vehicle.

May 06, 2010 | 2004 GMC Savana

1 Answer

How to change brake discs yourself on hyundia accent s reg


changing the disc brake yourself in the sense u wanna change the caliper and the brake disc? whole assembly?? i ll let u know both steps. first make your vehicle stand on a tripod stand or screw jack. now just bend inside to see the caliper.with the help of an extendable spanner remove all the screws of the caliper. now the caliper comes out. now to remove the disc use the allen keys to screw out the disc which is screw around the hub. replace it with a new disc and caliper. insert the brake hose into the new caliper and bleed the system. Thats it...

Jan 17, 2010 | Hyundai Motor 1995 Accent

1 Answer

How to replace 99 gmc 3/4 tom brake rotors


Removal & Installation
  1. Remove 2/3of the brake fluid from the master cylinder.
  2. Raise and support the vehicle.
  3. Remove the tire and wheel assembly.
  4. Remove the front wheel hub extension (dual wheel vehicles only).
    • Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning.
    • Mark the relationship of the front wheel hub extension to the hub
    • Remove the front wheel hub extension bolts
    • Remove the front wheel hub extension from the vehicle. It may be necessary to tap around the perimeter of the hub extension with a rubber mallet to loosen it from the hub
  5. Mark the relationship of the rotor to the hub.
  6. Remove the caliper and mounting bracket as an assembly.
  7. Hang the caliper and the mounting bracket assembly from the suspension using mechanics wire.
  8. Remove the rotor.
  9. If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor (25 series only).
    • Clean all the surface areas and the threaded holes of contamination
    • Generously apply penetrating oil or the equivalent to the hub/rotor area
    • Insert (2) M10 x 1.5 bolts (jack screws) into the threaded holes of the rotor
    • Tighten both bolts evenly to force the rotor from the hub.
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To install:
  1. Clean all rust and contaminants from the both side of the rotor and the hub flange.
    NOTE If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor.

  2. Install the rotor.
  3. Install the caliper and the mounting bracket as an assembly.
  4. Install the tire and wheel assembly.
  5. Remove the safety stands.
  6. Lower the vehicle.

Oct 25, 2009 | 1999 GMC Sierra

1 Answer

Removing front calipers to 2003 vw passat w8


go to a tool store and ask for an easy-out, this is a specialty tool placed on a drill to grip stripped screws and broken bolts

Apr 27, 2009 | Volkswagen Passat Cars & Trucks

1 Answer

Rear brake pad installation 99 volkswagen passat


If you can't see diagrams(sometimes happens) let me know and I will get them to you

  1. Raise and support the vehicle. Remove the rear wheels.
  2. If equipped, disconnect the brake pad wear sensor from the harness.
  3. Counterhold the lower sliding pin using a thin open-end wrench and remove the caliper-to-sliding pin hex bolt.
  4. Pivot the caliper upward or if necessary remove the upper caliper-to-sliding pin hex bolt.
  5. Using 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.
0900c152800c30b8.jpgUse a thin open-end wrench to . . . 0900c152800c30b7.jpg. . . support the caliper sliding pin when removing the caliper mounting bolt 0900c152800c30d7.jpgUse a disc brake caliper piston retracting tool that will rotate the caliper piston as it is pressed into the caliper 0900c152800c30d8.jpgThe rear caliper piston is slotted to allow a retracting tool to rotate the piston when replacing the brake padsTo install:
  1. Clean 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.
  2. 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.
  3. Lubricate the slider bolts with approved brake grease.
  4. Install 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.
  5. Replace all removed caliper-to-sliding pin bolts and torque to:
  6. 1990-97 Passat models: 25 ft. lbs. (35 Nm)
  7. 1998-00 Passat models: 22 ft. lbs. (30 Nm)
  8. If 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.
  9. Install the 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:
  10. M12 x 1.5 lug bolts: 81 ft. lbs. (110 Nm)
  11. M14 x 1.5 lug bolts: 89 ft. lbs. (120 Nm)
Feel free to contact if you have any questions

Nov 15, 2008 | 1999 Volkswagen Passat

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