Disc Brake System: Service and Repair

Rear Brakes Assembly Overview, CII 38 and C II 41 Brake Calipers

• Use brake filler/bleeder unit (VAS 5234) or extraction device (V.A.G 1869/4) to extract brake fluid from brake fluid reservoir.

• Before removing brake caliper or disconnecting brake hose, brake pedal depressor (V.A.G 1869/2) must be inserted (this dissipates pressure).





1 Cover Plate

2 Brake Disc

• 16 inches: 286 mm diameter

• 17 inches: 310 mm diameter

• Thickness 16 inches: 12 mm

• Thickness 17 inches: 22 mm

• Wear limit 16 inches: 10 mm

• Wear limit 17 inches: 20 mm

• Always replace pads on both sides of axle if worn.

• To remove, first remove brake caliper and carrier

3 Inner TORX(R) Bolt

• 4 Nm

4 Multi-Point Socket Head Bolt

• Always replace after removal

• 90 Nm plus an additional 90° turn

5 Brake Carrier with Guide Pins and Protective Cap

• Supplied as an assembled replacement part with sufficient grease on guide pins

• If protective caps or guide pins are damaged, install repair kit. Use supplied grease packet to lubricate guide pins

6 Anti-Rattle Spring

• Always replace when pads are replaced

7 Brake Pads

• Thickness 11 mm without backing plate

• Wear limit: 2 mm without backing plate

• Check the thickness.

• Must always be replaced together on both sides of axle

• Removing and installing, refer to => [ Brake Pads ] Rear Brakes, CII 38 and C II 41 Brake Calipers

8 Brake Pads

• Thickness: 11 mm without backing plate

• Wear limit: 2 mm without backing plate

• Check the thickness.

• Must always be replaced together on both sides of axle

• Removing and installing, refer to => [ Brake Pads ] Rear Brakes, CII 38 and C II 41 Brake Calipers

9 Anti-Rattle Spring

• Always replace when pads are replaced

10 Brake Caliper

• Do not remove brake hose when replacing brake pad

• Removing and installing, refer to => [ Brake Caliper ] Rear Brakes, CII 38 and C II 41 Brake Calipers

• Servicing, refer to => [ Rear Brake Assembly Overview, CII 38 and CII 41 Brake Calipers ] Rear Brake Assembly Overview, CII 38 and CII 41 Brake Calipers

• Perform a basic setting after servicing or replacing.

11 Hex Bolt, Self-Locking

• Replace

• 35 Nm

12 Bracket

13 Brake Line

• 14 Nm

14 Retaining Clip

15 Seal

16 Parking Brake Motor

17 Inner TORX(R) Bolt

• 12 Nm

18 Brake Hose

19 Inner TORX(R) Bolt

• 12 Nm