Running gearRepairing rear brake caliper
| Repairing rear brake caliper |
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| Apply thin coat of brake cylinder paste to brake cylinder, piston and seals. |
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| When carrying out repairs install all parts supplied in repair kit. |
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| New brake calipers are filled with brake fluid and are pre-bled. |
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| When carrying out repairs it is essential to appropriately pre-bleed the brake calipers (without brake pads) before installing in the vehicle → Fig.. |
| 1 - | Self-locking bolts, 35 Nm |
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| When loosening and tightening, counter hold on guide pin. |
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| Remove with a plastic wedge → Fig.. |
| 3 - | Piston with automatic adjustment |
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| Remove from brake caliper housing: |
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| Vehicles up to 07.87 → Fig.. |
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| Vehicles as of 08.87 → Fig.. |
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| Installing into brake caliper housing → Fig.. |
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| Position with outer sealing lip onto piston → Fig.. |
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| Insert with inner sealing lip into groove in brake caliper housing → Fig.. |
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| Do not damage sealing lips when positioning or inserting. |
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| Apply thin coat of brake cylinder paste to threads before screwing in. |
| 7 - | Brake caliper housing with lever for handbrake cable |
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| If a leak exists at the handbrake cable lever, renew brake caliper housing. |
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| After repairing, pre-bleed brake caliper housing → Fig. |
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| Lubricate before installing protective cap |
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| Insert onto brake carrier and guide pin |
| 10 - | Brake carrier with guide pin and protective cap |
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| Supplied as replacement part, assembled with sufficient grease on guide pins. |
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| If protective caps or guide pins are damaged, install repair kit. Use grease sachet supplied to lubricate guide pins. |
| Removing piston from brake caliper housing, vehicles up to 07.87 |
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| Unscrew piston by turning anti-clockwise. |
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| Removing piston from brake caliper housing, vehicles as of 08.87 |
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| Unscrew piston by turning anti-clockwise. |
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| Use reworked wedges -V.A.G 1474/5- to do this. |
Note | Reworking wedges -V.A.G 1474/5- → Fig. |
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| Place protective seal with outer sealing lip on piston. |
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| Inserting inner sealing lip of protective cap into grove in brake caliper housing |
| Use reworked wedges -V.A.G 1474/5- to do this. |
| When doing this hold piston in front of caliper housing. |
Note | Reworking wedges -V.A.G 1474/5- → Fig. |
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| Installing piston into brake caliper housing |
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| Screw piston in to stop by turning clockwise. Press firmly onto piston while screwing it in. |
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| In vehicles as of 08.87, use tool -3131- instead of Allen key → Fig. |
Note | The outer sealing lip of the protective cap will then lock in the groove on piston. |
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| Pre-bleeding brake caliper |
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| Open bleed valve and fill with brake fluid using a standard bleed bottle until brake fluid flows out of the threaded hole (brake hose connection) without bubbles. Close bleed valve. |
Note | Position brake caliper as illustrated to pre-bleed. |
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01 Steering & suspension
