Campaign - Rear Brake Damper Kit Installation
NOTP
DATE
November 1996
Subject:
Complaints Of Noise From Rear Disc Brakes On 1996 Model Volkswagen Vehicles
Dear Volkswagen Dealer:
This is to inform you of a service action which will eliminate potential braking noise on 1996 model Volkswagen Passat, Jetta and GTI vehicles equipped with rear disc brakes.
Condition
It is possible that owners may complain of noise coming from the rear disc brakes.
Corrective Action
Dealers are to install a brake damper Kit, part number 1H0 698 998B or 1H0 698 998C, in vehicles within the vehicle identification number ranges listed below.
Vehicle Identification Numbers
Parts Supply
An initial supply of brake damper kits to cover immediate requirements will be shipped to you automatically, within the next two weeks. Additional kits may be ordered from your parts depot. Please refrain from over-ordering this damper kit
Vehicle Update Schedule
As there will be no owner notification mailing, it is imperative that the brake damper kit is installed in all applicable vehicles as follows:
- Check and, if necessary, install brake damper on all (VIN range) vehicles in your inventory prior to retail delivery.
- Vehicles coming into your dealership for scheduled routine maintenance or repair should be checked and, if necessary, updated before the vehicle is returned to the customer.
Some of the affected vehicles may have already been updated at port facilities with a damper kit.
This action must be performed at no charge to the customer.
Installation Procedure
^ Check vehicle for previous installation of kit If kit is not already installed, proceed as follows:
^ Remove rear portion of center console to gain access to band brake cable adjusting nuts.
^ Mark/note position of hand brake cable adjusting nuts and loosen nuts and detach each cable from the rear caliper actuating arm.
^ Remove clip securing hand brake cable housing to retaining bracket and pull each cable assembly out of bracket.
^ While the cable is disconnected, ensure the actuating arm on both left and right side calipers contact the stop tab on the cable retaining bracket.
-If OK:
^ Remove the 6 mm Allen head screw securing the cable retaining bracket to the caliper, and replace the bracket with (integrated vibration damper) part number 1H0 698 998B or 1H0 698 998C.
^ Be sure to use the new screw from kit, part number 1H0 698 998B or 1H0 698 998C, and torque to 10 Nm (7 ft lb).
-If Not OK:
^ Remove the 6 mm Allen head screw securing the cable retaining bracket to the caliper and remove the bracket.
^ Remove the 8 mm nut retaining the caliper actuating arm and note the position of the arm.
^ Pull the actuating arm out far enough to rotate one spline counter-clockwise and reinsert in this position.
^ Reinstall 8 mm nut and torque to 20 Nm (15 ft lb).
^ Install the new bracket (with integrated vibration damper) from kit, part number 1H0 698 998B or 1H0 698 998C, in place of the original one.
^ Be sure to use the new screw from kit, part number 1H0 698 998B or 1H0 698 998C, and torque to 10 Nm (7 ft lb).
^ Reinstall hand brake cable assemblies into the new retaining brackets and reinstall retaining clips.
^ Re-attach hand brake cables to actuating arms.
^ Pump brake pedal to seat pads.
^ Tighten hand brake adjusting nuts towards marked position, check for proper number of clicks in setting hand brake.
With hand brake lever released, check the clearance between the actuating lever and the stop at each rear brake caliper. - Maximum gap between the lever and stop is 1.5 mm (0.059 in.)
Ensure that both rear wheels turn freely.
Check to ensure that there is no interference between the hand brake lever mounting nut with hand brake applied.
Ensure noise is eliminated.
Replacement Time/ Reimbursement
It is important that you enter the correct reimbursement data into the system only for VINs showing a TP code in the V-Crest system. This includes vehicles which were previously updated at port facilities, and no longer require the kit installation.
TP Data Entry Procedure
The system automatically enters the labor and part number application to the above listed reimbursement codes.
Dealer Obligation
Dealers are requested to promptly schedule an appointment for any vehicle owner with a rear brake noise complaint to have this damper kit installed. It is equally important to ensure that affected vehicles are updated with the damper kit while in your dealership for repair or maintenance service. Affected vehicles are identified on your V-Crest information system with the TP code.
Service Help
If you have any questions regarding this service action program or any other recall or service action campaign, please contact me at (810)340-4850 or John von Hollen at (810)340-4858.
Dealer Personnel Information
Please provide a copy of this communication to every person in your dealership who has campaign-related responsibilities.
Thank you for your cooperation.