Selecting and replacing the Passat B7 brake discs: for beginners

Replacing front wheel brake pads (for use on VW Passat B7 model)

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Front wheel brake pads

Note : Brake pads should ALWAYS be replaced as a set of 4 (two per side).

Note : The replacement of the brake pads on the right side is described below. The replacement on the left side is done in the same way.

1. First check the brake fluid level in the brake master cylinder reservoir. If it is at or near the “MAX” mark, siphon off some fluid from the tank. Otherwise it will overflow when new pads are installed.

Loosen the wheel bolts. Lift the front of the vehicle with a jack, place it on a jack, or raise the vehicle on an elevator. Remove the wheel bolts and remove the front wheel.

3. 3. Turn the steering wheel all the way to the right or left, depending on which side you are replacing the brake pads. In our case it is to the right. Also clean the brake mechanism from dust and dirt.

Disconnect the electrical connector of the brake pad wear sensor.

5. Use a screwdriver to pry and then remove the brake pad retaining spring from the brake caliper, keeping the spring in place with your free hand.

6. Use a screwdriver to pry and then remove the protective caps of the two brake caliper pins.

7. Use a TORX wrench to unscrew the brake caliper pins from the brake caliper.

8. Remove the brake caliper with brake pads and hang it with a suitable thick wire on the strut spring.

Caution : The brake caliper must be suspended from a sturdy metal wire or similar each time it is removed from its mountings and the flexible brake hose remains connected to it. Failure to do so will cause the weight of the caliper to act on the flexible brake hose, which can damage the hose and then cause the brake fluid to leak.

9. Remove the old brake pads from the brake caliper and from the bracket holder and discard them.

10. Using the piston sinking device or any other tool, for example, an ordinary carpenter’s clamp will do, push the piston completely into the brake caliper.

While pushing the piston, watch the level of brake fluid in the reservoir.

Clean the contact surfaces of the caliper with a metal brush and remove any rust (do it carefully so as not to damage the cylinder dust cap).

Caution : Do not blow out the brake system with compressed air. Toxic brake dust is hazardous to health. It accumulates irreversibly in the lungs and can affect the respiratory system.

Also clean off dirt and rust from the seats of the brake pads on the brake caliper bracket.

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13. Apply a special high-temperature brake grease to the brake caliper bracket in those places where the brake pads will be in contact with the bracket (see photo below).

14. Also apply a special high-temperature lubricant for the brakes on the new brake pads in those places where they will be in contact with the brake caliper.

15. Insert the outer brake pad into the brake caliper bracket-holder.

16. Insert the inner brake pad (with retaining spring) into the brake caliper piston and then install the brake caliper assembly onto the caliper bracket.

Caution : The surface of the brake pads and the brake disc must be free of oil and paint.

17. Lubricate with a special high-temperature lubricant for the brakes guide pins, insert them into the brake caliper and tighten. Install the protective caps in place.

18. Using a screwdriver, carefully install the brake pad retaining spring on the brake caliper.

19. Connect the electrical connector of the brake pad wear indicator.

20. Change the brake pads on the other side in the same way.

21. Install the wheel and lower the vehicle to the ground.

22. Press down hard on the brake pedal several times so that the brake pads are in their working position.

23. Check and, if necessary, restore the brake fluid level in the expansion tank. Tighten the cap on the reservoir.

24. Test drive and brake a few times to remove any foreign matter from the running surfaces and allow the brake pads to run in.

Passat b7 brakes audi

Hi, I have a car with ABS and ESP, changed all the discs, pads and brake fluid and the rear caliper – missed the level in the tank – blew air out of the system. Pumped the old man’s way from the rear right to the front left. Only now brakes weakly the first time, and if the second press – even a pedal kolom and does not brake. I connected VAG Com – no errors. I wanted to pump with VAG Com. I found this instruction:

Select: ABS – Basic settings – 001 group, enter, then follow the instructions:

1. He is asking you to press the pedal and hold it. Press and hold it, pedal goes almost to the edge 2. In a few seconds the hydromodule pump switches on and the pedal goes back to its starting position with the effort of your legs. Release the pedal. 3. Check for opening leaking valves on front wheels (both of them), open them, push enter. In 10 seconds the pump will switch on and pump out the fuel oil from the opened valves on the front wheels (use tubes and bottles which should be prepared beforehand). As soon as the pump has switched off close both valves. 4. He asks to press the pedal 10 times. We press. We press eptegi all repeated from step 1.

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Do this as many times (by my count a total of 8), until the inscription appears on the screen, something like: “The air is partially removed.

Then you need to pump the brakes in the usual way. But in no way letting the system dry out, otherwise you will have to do it all over again.

I choose ABS, I put my login 09557, I press basic settings, I choose 001, I get the message that VAG 311.2 was not available. The ESP and ABS lights flashed on the dashboard, but when I drove off, they went out. What can be the problem? Wrong VAG, wrong cord or what am I doing wrong?

Topic: Replacing the stock brakes with the stock brakes.

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Touareg Registration Date: 08-31/2011 Address: St.Petersburg Messages 2,458 entries in my diary 5

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Replacing the stock brakes with… stock brakes.

Where it all started: The original brakes (V6 – 312 mm at the front, 256 mm behind), basically I was fine, but several times I noticed that when braking heavily on the highway from 140 to 90, the brakes became sluggish, if you can say so … And I drive fast, far and often…… Well in the end, as has been repeatedly written on the forum and that statement with which I completely agree “any tuning should start with the brakes”.

Search of alternatives: I’ve searched and came to conclusion that I am not ready to rely on turners (to install the same Brembo, which are sold now, it is necessary to produce adapters adapter) and decided to put original Lucas brakes from W8 (by the way, similar brakes were on Audi A4/A6/S6/A8). The W8 had 321mm as well as 334mm brakes. Both used a dual-piston caliper, but the 334 had two pads and the 321 had four pads per caliper.

Plus, for 334 mm. you need at least 17 wheels…., it’s in theory, in practice and 321 mm. do not fit in 16, do not also forget about the offset of the disk. I have 37 and 45. Full “stock-install”. Minus was found only one – obsolete as many believe the caliper guide system.

What was done: To install 321 discs requires changing the knuckles, since the bracket has a different mount. Immediately were bought hub bearings Fag (713610030 most often go in the original), and, respectively, calipers and brackets. First of all everything was disassembled and cleaned. Since the dust bags were in bad shape I bought TRW SJ 1242 repair kit (two dust bags and two glands).

After powder coating the calipers and brackets, and cleaning the guides of the caliper, proceed to the assembly, pre-lubricating all the rubber with silicone grease. Fingers cleaned with sandpaper on 1400, having clamped them in the screwdriver.

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To install new cams, in order to avoid surprises, just in case, I bought the original front suspension mounting kit (I can’t find the number unfortunately). I will not stop on installation of cams and hub bearings, as there are photo reports in the knowledge base. To install on the rear 269mm wheels we needed only wheels and calipers (4D0 615 425 B) – calipers are the same. A similar cleaning and painting job was done. At the same time it was decided to change the finger guides, oil seal and brake cylinder dust cap. Two TRW repair kits were purchased (also comes in the original). TRW ST 1160 finger guide repair kit (dusters and guides themselves with high-temperature grease, no mounting balls. ) and TRW SJ 1039 (brake cylinder packing and dust cap).

New brake hoses were also purchased. I also used TRW hoses (front TRW PHA 294 (exactly 294, not 295 as Exist suggested) and rear TRW PHD 557). Reinforced hoses refused because no one had explained the rationale for their installation. In the choice of discs ran into a small problem ….. There are almost no analogues to original disks from VW to 321…. So started to pick from: Otto Zimmerman and Brembo. But the choice also turned out not great, from disks with perforation I refused at once, as on three cars which saw me – disks after 10 were covered by cracks on perforation, therefore have been bought Otto Zimmerman with a dusting (100.3324.20). Rear discs were also from Otto Zimmerman, but without dusting (100.1239.00). Choice of pads was rather great – Brembo, ATE, EBC, Ferodo, preference was given to well-proven Textar pads (front 2328001, rear 2355402).

What the result: 1. Front – 2-piston calipers Lucas under 321 mm disks. Discs Otto Zimmerman Coast Z. Textar pads.

2. Rear – single-piston calipers Lucas under 269 mm disks. Discs Otto Zimmerman. Pads Textar.

Brake tuning for Volkswagen Passat B7

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  • Brand: TA-Technix
  • Fitting Position: Front Axle
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  • Product type: Brake discs
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  • Car: Volkswagen Passat B7
  • Brand: TA-Technix
  • Fitting Position: Rear Axle
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  • Product type: Brake discs
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What can I say. The product is good, my 280hp Scirocco is not bad, but the brake pads have not frayed yet. The rotor looks very different from the stock. Both perforation and grooves. I will make a more detailed test in a month.

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Selecting VW Passat B7 Brake Discs

Brake discs wear out after 100,000 miles. With regular use of the car, in harsh operating conditions, this figure is reduced by several tens of thousands of kilometers. Experienced mechanics advise replacing brake discs in time, so as not to get into an accident due to poor brake response on the Volkswagen Passat B7.

Let’s see what kind of brake discs will be required to perform the procedure specifically for a car of the German brand.

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What TD set by the manufacturer and what to replace, if there are no original

Each spare part has its own original number or also called an item number. Thus, for the brake discs installed on the Volkswagen Passat B7, its own designation is used:

  • front – VAG 1K0 615 301 AA;
  • rear – VAG 1H0698 45 1E.

Of analogues, experienced mechanics advise to choose the following brake components:

  • front brake discs from Textar – 92120505;
  • Rear TDs from the manufacturer – B1G21201691.

These brake components are made of metal with a high-carbon coating. They are not afraid of high temperatures.

Attention! Experienced mechanics advise to change the parts only in pairs. Otherwise there will be no point in replacing one brake disc, as the load on it will increase as the wear of the part that was not to be replaced. You will end up having to buy two pieces of discs again after a short time and replace them again.

Now you know which TDs to choose. Let’s take a look at how the front and rear TDs are replaced on the Passat B 7.

The process of replacing the front discs of the Volkswagen Passat B7

If you are a beginner and are wondering how to change the front and rear discs, these instructions will help you to do it without involving auto services.

  1. Install the car on a flat surface.
  2. First you will need to remove the wheel. Unscrew the bolts on the front wheel, so that it is a little free, and lift it with a jack.
  3. Now you will have to unscrew the bolts to the end and remove the wheel.
  4. Take a seven allen key and unscrew the two guide pins.
  5. Then you remove the caliper.
  6. Now you hang that caliper on a wire, putting it to the side so it doesn’t get in the way.
  7. Clean with WD 40 from the rusty dirt on the bolts of the caliper.
  8. Unscrew the screws with a wrench for 17.
  9. Remove the bracket and the brake disc.
  10. Take a metal brush and clean any rust or dirt from the hub.
  11. Lubricate the adjacent hub surface with graphite or copper grease.
  12. Wipe off the new brake disc with solvent and install it on the hub.
  13. Use a special tool for further work. Namely you will need to press in the brake pistons. On the Passat B7 you will not only have to push it in, but you also need to crank it. Then you will need to install the bracket.
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Experienced mechanics advise to check the brake fluid before pushing the pistons in. If there is a lot of it, you will need to pump it out.

After installing the brace and bracket, install all other items in reverse order.

Warning. It can happen that the brake disc is too stuck to the hub and difficult to remove. Also use WD 40 to remove excess dirt and dissolve the rust.

Pay attention to the thickness of the pads when replacing discs. If it is 2mm thick, you need to replace the pads as well.

Replacing Rear TDs on a Passat B 7

The procedure for replacing the TD is almost no different from replacing the brake elements on the front wheels.

  1. Place the Volkswagen Passat B 7 on a level surface or a pit.
  2. Lock the front wheels and remove the rear wheels.
  3. Now it is necessary to dismantle the caliper.
  4. Remove the upper and lower guides. To do this, take a wrench for 17 and hold the nut, and unscrew the bolt with a thirteenth wrench.
  5. Suspend the caliper so that it does not hang from the hose.
  6. Remove the pads.
  7. Now it’s time to remove the pads.
  8. It can be difficult to remove. To do it again we use WD

After you remove it, put on the new TD and assemble all the components in reverse order. Be sure to open the cap on the brake fluid reservoir so that the pads will fit easily and the pistons will press in.

After replacing all the brake pads, drive the car. Press on the brake pedal. If it squeezes down easily, it means there may be air in the brake system. Pump it to get rid of any extra air in the system.


As you can see, finding and replacing brake discs is pretty easy. The main thing is to consider the recommendations of experienced mechanics, and, if you are doing a TD change for the first time, invite a friend who understands cars to help.

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