C 38

Disc brakes, assembly overview





Special tools, testers and auxiliary items required
^ Torque wrench V.A.G1331
^ Torque wrench V.A.G1332
^ Torque wrench V.A.G1410
^ Brake pedal depressor V.A.G1869/2 or equivalent

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 draw off brake fluid from the reservoir, use a bleed bottle which is used exclusively for brake fluid. Brake fluid is poisonous and may on no account be sucked out by mouth via a hose!
^ install brake pedal depressor V.A.G 1869/2 before removing a brake caliper or disconnecting a brake hose from the brake caliper.

Rear disc brakes, assembly overview:

1 - Phillips-head screw, 4 Nm
2 - Brake disc
^ Ventilated brake disc: 256.00 mm diameter
^ Thickness 22 mm
^ Wear limit 20 mm
^ When worn, always replace both sides

3 - Brake disc
^ Non-ventilated brake disc: 232.00 mm diameter
^ Thickness 9 mm
^ Wear limit 7 mm
^ When worn, always replace both sides

4 - Cap

5 - Self-locking 12-point nut, 175 Nm
^ Replace each time after removing

6 - Wheel hub with wheel bearing and rotor
^ Replace each time after removing
^ Only replace complete

7 - Hex bolt, 60 Nm
^ With dished spring washer

8 - Splash plate
9 - Stub axle
10 - Parking brake cable

11 - Axle beam
12 - Right Rear ABS Wheel Speed Sensor G44 / Left Rear ABS Wheel Speed Sensor G46
^ Before inserting sensor, clean mounting hole inner surface and coat with lubricating paste G 000 650

13 - Hex socket head bolt, 8 Nm
14 - Hex socket head bolt, 65 Nm
15 - Brake carrier with guide pins and protective cap
^ Supplied as replacement part, assembled with sufficient grease on guide pins
^ If protective caps or guide pins are damaged use repair kit. Use grease packet supplied to lubricate guide pins.

16 - Brake hose/brake line
^ With banjo bolt and seals
^ Banjo bolt to brake caliper tightening torque 35 Nm
^ Do not disconnect brake hose when changing brake pads

17 - Self-locking hex bolt, 35 Nm
^ Always replace

18 - Brake caliper
^ Do not disconnect brake hose when changing brake pads
^ Adjust parking brake cable first after maintenance or replacement

19 - Brake pads
^ Thickness 12 mm without backing plate
^ Wear limit: 7 mm including backing plate
^ Always replace both sides on an axle.

20 - Pad retaining spring
^ Always replace when changing pads