VW Passat B5

since 1996 release

Repair and operation of the car

Foltsvagen Passat B5
+ Maintenance instruction
+ 1. Maintenance
+ 2. Engines
+ 3. Cooling system
+ 4. Fuel system
+ 5. Engine management
+ 6. Exhaust system
+ 7. Transmission
+ 8. Running gear
+ 9. Steering
- 10. Brake system
   10.2. General information
   10.3. ABS/EBV/EDS/ASR/ESP systems
   10.4. Check of the vacuum amplifier of brakes
   - 10.5. Replacement of front brake shoes
      10.5.1. Replacement of front brake shoes on Lucas support
   10.6. Replacement of back brake shoes
   10.7. Check of a brake disk
   10.8. Brake disk
   10.9. Pumping of the hydraulic brake system
   + 10:10. Brake pipelines and hoses
   10:11. Stoplight switch
   10:12. Lever of the emergency brake
   10:13. Adjustment of the emergency brake
   + 10:14. Cable of the emergency brake
   10:15. Main malfunctions of brakes
+ 11. Body
+ 12. Heating, ventilation
+ 13. Electric equipment

10.5. Replacement of front brake shoes


1. Weaken bolts of fastening of a forward wheel, then lift a forward part of the car and fix on supports. Unscrew bolts of fastening and remove a wheel.

Surely you make replacement of all blocks on one axis of the car even if the limit of wear was reached by only one block. If brake shoes are repeatedly established, before removal they need to be marked.

2. In the presence remove the wear sensor from an internal brake shoe and disconnect the electric socket of the sensor.
3. Using a screw-driver edge as the lever from the outer side of a support remove the fixing spring.
4. Remove dustproof caps from the internal ends of the directing bolts.
5. Unscrew the directing fingers from a support.
6. Lift a support with an internal block and, using a soft wire, tie up it to a forward rack.

The brake support should not hang on a brake hose. The brake hose should not stretch or be overwound.

7. Remove an internal block from the piston of a support and an external block from the holder of a support.


Arrangement of front brake shoes before installation of a support


Do not press a brake pedal at the removed brake shoes.

After installation of new brake shoes avoid sharp braking during the first 200 km of a run of the car.

1. Purify dust and dirt from a support, and a rust from edge of a brake disk. If blocks are suitable for further operation, clear them, using a wire brush and rags.
2. Check a brake disk for existence of cracks, especially around openings under bolts of fastening of a wheel, and also for existence of wear or mechanical damages and, if necessary, replace it.
3. Measure thickness of a brake disk.
4. If new brake shoes are established, using special adaptation, press the piston into a support. For cave-in of the piston in a support it is possible to use a wooden core or the handle of the hammer. At the same time you watch that the piston did not warp also the surfaces of the piston and a boot were not damaged. At a piston vdviganiye brake fluid is forced out from the brake cylinder in a broad tank therefore constantly watch liquid level in a tank, and if necessary, pump out its small amount from a tank.
5. Check that dredging on the piston of a support is located on a vertical axis. If necessary turn the piston in the correct situation.
6. Apply a thin film of lubricant for the brake system on the surfaces of brake shoes interfaced to a support.
7. Establish an internal block on a support, at the same time the spring bracket has to be established in dredging of the piston.
8. Establish an external brake shoe.
9. Establish a support with an internal block on the holder of a support. Screw in the directing fingers of a support and tighten their moment 25 Nanometers.
10. Establish dustproof caps on the directing support fingers.
11. Establish the fixing spring on a support. At the same time the ends of a spring has to settle down in support openings.
12. In the presence install the new sensor of wear on an internal brake shoe.
13. Similarly replace brake shoes on the second forward wheel.
14. Establish wheels and lower the car on the earth. Tighten fastening bolts the moment of 120 Nanometers.
15. Several times press a brake pedal that brake shoes nestled on a brake disk.
16. Check the level of brake fluid in a tank.