How to Replace the Rear Brake Pads on a 2002 VW Passat

The 2002 Volkswagen Passat was equipped with a 2.8-liter V-6, a 1.8-liter turbocharged four-cylinder, or a 4.0-liter W-8 engine, depending on the sub-model. The 2002 Passat was available in front-wheel drive or all-wheel drive. The 2002 Passat had rear drum brakes on the base model, but had the option of a four-wheel disc-brake system. The rear calipers on the 2002 Passat have rotating pistons that require a special tool, available at most auto parts stores.

Instructions

1

Raise the hood on the Passat. Inspect the brake fluid level in the reservoir. Remove brake fluid with a turkey baster or bottle siphon, until the fluid is about 1/2 inch below the "Full" mark. Install the reservoir lid and tighten it.

2

Loosen the rear wheel lug bolts with a tire iron, but do not remove them. Raise the rear of the Passat with a jack. Place jack stands beneath the rear axle beam, about 6-inches inward from the rear wheels. Remove the rear lug bolts, then remove the rear wheels from the car.

3

Sit in the vehicle and make sure the parking brake handle inside the car is in the resting or off position. Step out of the vehicle and position yourself under the rear of the Passat. Insert a screwdriver between the two arms on the parking brake assembly, on the rear of the caliper. Hold the assembly still while removing the hex bolt from the rear of the parking brake assembly with a ratchet and socket. Pull the parking brake lever attached to the cable free from the parking brake assembly with the screwdriver.

4

Remove the caliper bolts from the rear of the caliper with a ratchet and socket, while holding the caliper slide pins still with an open-end wrench. Remove the caliper from the brake assembly with a small pry bar if needed. Hang the caliper from the rear coil spring with a metal clothes hanger or hook. Do not let the caliper hang freely by the rubber hose it is attached to.

5

Remove the old brake pads from the caliper bracket by hand. Inspect the anti-rattle clips at the top and bottom of the caliper bracket, and replace them if they are bent or damaged. Inspect the rear brake rotor for cracks, pitting or rust. Measure the rotor thickness with a tape measure. if the rotor is damaged or is less than 3/8 inches thick, replace the brake rotor at this time.

6

Retract the caliper piston into the caliper body, using a 3/8-inch drive ratchet, extension and caliper-rotating tool. Turn the piston clockwise while applying inward pressure on the piston. Continue turning until the piston is completely retracted into the caliper. Remove the caliper guide pins from the rear of the caliper. Thoroughly grease the pins with caliper grease, then insert them back into the caliper. Replace the small rubber boots on the rear of the caliper at this time, if they are dry rotted or torn.

7

Install new brake pads onto the caliper bracket. Install the rear brake caliper onto the brake assembly. Install and tighten the caliper bolts to 26 foot-pounds with a torque wrench and socket. Install the brake cable assembly back onto the rear parking brake assembly. Install and tighten the brake cable nut with a ratchet and socket, while holding the parking brake assembly still with a screwdriver. You may have to loosen the nut on the adjuster arm below the cable arm, to fit the cable arm back into place. Tighten both fixtures with a ratchet and socket.

8

Repeat steps 3 through 7 to complete the rear brake pad replacement on the second side of the Passat. Fill the brake fluid reservoir if necessary, until the fluid level is near the "Full" mark. The fluid level may be on an angle due to the incline of the car. Use the middle of the reservoir fluid level as your guide for how full the reservoir is. Install and tighten the reservoir cap.

9

Gently seat yourself in the driver's seat of the Passat. Pump the brake pedal slowly about 40 times. This will seat the caliper pistons against the new brake pads. If the pedal does not stiffen after five or six pumps, stop pumping and bleed the rear brakes. Exit the Passat when you have completed pumping the brakes and have a solid brake pedal.

10

Install the rear wheels onto the Passat. Insert a guide pin or punch awl through one of the lug bolt holes to align the holes on the hub with those on the wheel. Insert all of the lug bolts and begin threading them by hand, to ensure proper threading. Tighten the lug bolts snug with your tire iron. Raise the Passat off of the jack stands, then remove the stands and lower the car to the ground. Apply 90 foot-pounds with a torque wrench and socket. Double check the brake fluid reservoir with the car lowered onto level ground.