How to Retract the Rear Disc Brake Caliper on a 1996 VW Passat

The 1996 Volkswagen Passat was equipped with a 2.0-liter in-line four-cylinder engine in the base model. A 1.9-liter four-cylinder turbo diesel and a 2.8-ltier V-6 were optional engines for the 1996 Passat. The Passat was available with four-wheel disc brakes. Removing the rear brake calipers to retract the caliper piston requires removal of other brake parts. The 1996 Passat rear calipers have a rotating piston that twists inward and outward.

Instructions

1

Loosen the rear wheel bolts on the Passat, using a tire iron. Raise the rear of the car with a jack. Place jack stands at both ends of the rear axle beam, about six inches inward from the rear wheels. Lower the Passat onto the jack stands. Remove the rear wheel bolts from both wheels, then remove the rear wheels.

2

Spray both caliper bleeder screws on the rear caliper with aerosol penetrating spray. Allow the spray to set for 10 to 15 minutes. Remove the small bleeder screw rubber caps, if equipped.

3

Lie beneath the rear of the Passat on one side. Remove the hold-down nut from the parking brake swivel lever, using a ratchet and socket. Disconnect the swivel and parking brake from the brake caliper. Place a drain pan beneath the brake assembly you are working on. Open the bleeder screw clockwise, with an open-end wrench.

4

Insert a caliper piston rotation tool against the caliper piston. Make sure you are using the correct fittings on the piston by attempting to turn the piston by hand. If the tool is locked into the piston and you cannot turn it by hand, you have the correct side of the tool. Install a ratchet and six-inch extension onto the rotating tool. Turn the caliper piston clockwise until it is completely retracted into the caliper body and hold it tight with the ratchet. Tighten the bleeder screw snug, using your open-end wrench.

5

Place the caliper onto the brake assembly. Install the caliper mounting bolts and tighten them to 25 foot-pounds. Use a 1/2-inch-drive torque wrench and socket to tighten the bolts. Install the parking brake swivel lever and tighten the nut with a ratchet and socket.

6

Install the rear wheels onto the Passat when you are finished performing your brake work. Insert a straight awl or punch through the wheel lug hole into the hub to line up the wheel bolt holes. Install the wheel bolt holes, removing the awl to install the final bolt. Tighten the bolts snug with a tire iron. Read the outer head of the lug bolt for the size, which is either an M12 x 1.5 or a M14 x 1.5 . Raise the car off the stands and remove them.

7

Lower the Passat to the ground. Tighten the rear wheel bolts to 81 foot-pounds, if the bolts are M12 x 1.5 bolts. Tighten the rear wheel bolts to 89 foot-pounds of torque if the bolts are M14 x 1.5 bolts. Use your torque wrench and a wheel nut socket to tighten the bolts.