I have a 2003 tiburon and I changed the rear rotors and pads but can't seem to get the caliper back on cause the lower guide pin doesn't slide like the upper one. I have never seen this before is this normal?

did you turn the rotors some times there ia ridge on the rotors that needs to be machined down.

Pacifica 2006-2008
Brake Calipers

• REMOVAL & INSTALLATION

Print I hope this helps,Good luck

Removal & Installation


NOTE Using a brake pedal holding tool, depress the brake pedal past its first inch of travel and hold it in this position. This will isolate the master cylinder from the hydraulic brake system and will not allow brake fluid to drain out of the reservoir while the brake lines are open.

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   Negative battery cable Rear wheels Banjo bolt retaining the brake hose to the caliper. Be sure to plug the end of the brake hose or cover it with a plastic bag to prevent contamination from entering the hydraulic system. Caliper guide pin bolts Caliper assembly from the brake adapter by rotating the bottom of the caliper away from the rotor, then lift the caliper with the pads away from the adapter abutment Brake pads by pushing (outboard) or pulling (inboard) from the caliper fingers and piston
   
   

   Fig. Brake hose banjo fitting (1), caliper guide pin bolt (2), caliper adapter (3), caliper (4), copper seal washers (5) and banjo bolt (6)
   
   

To install:

1. Completely compress the caliper piston
2. Install or connect the following:
   NOTE The outboard pads are side oriented, make sure the spring clip is installed so it is positioned downwards when the caliper is installed.
   
   
   Inboard pad clip against the piston cavity and press the pad until the clip is seated making sure the pad backing plate is flush against the piston
   
   
   Outboard pad making sure the locating pins are positioned against the ramps. Slide the pad onto the caliper and ensure the locating pins are squarely seated into the holes on the caliper and the pad is flush against the caliper fingers.
   
3. Make sure the abutment shims are in place on both slide abutments.
4. Retract the caliper guide pins to clear the caliper adapter bosses.
   
   Brake caliper. Staring with the upper end, position the caliper and shoes over the rotor and align the outboard pad upper edge with the caliper slide abutment. Rotate the lower end of the caliper into position Caliper guide pin bolts and tighten to 200 inch lbs. (23 Nm) Banjo bolt with new washers on each side of the hose fitting and tighten to 35 ft. lbs. (47 Nm) Wheels Negative battery cable
   
5. Bleed the brake system and road test the vehicle

Front brakes are very simple to do:

• Pull off the front tires.
• Remove the brake pads by removing the slide pin bolts where the piston assembly attaches to the caliper mounting bracket. The slide pin bolts are usually a 12 or 14mm bolt. Once the piston assembly is free slide the old brake pads out.
• Compress the piston back into the caliper by using a large pair of channel lock pliers or a c-clamp. If you don't do this, you won't be able to get the new pads on.
• Before you put the new pads on, replace the rotor.
• Remove the two bolts for the caliper mounting bracket. They are in the back and are bigger than the slide pin bolts. Usually a 17 or 19mm bolt.
• Pull off the caliper mounting bracket.
• At this point the old rotor should slide right off. If it doesn't slide right off, look for a screw in the center of the rotor, some cars will have a screw there to hold the rotor on. If there's no screw and it still won't come off, try tapping it with a hammer. If you're replacing the rotor, don't be shy.
• Put the new rotor on. Make sure to clean off any grease with brake cleaner that may be on the braking surface from packaging.
• Put the caliper mounting bracket back on.
• Put the new brake pads on. Make sure to use some anti-squeal grease on the back of the pads.
• Put the caliper assembly back on with the slide pins. Grease up the slide pins as well.
• Put the wheels back on.
• Make sure to pump your brakes 10 - 15 times before you drive off. Because you compressed the piston back into the caliper, the piston will not be contacting the brake pads unless you pump the brakes.

Good Luck!
~Brandon

A special tool is required to compress the caliper piston on the rear brakes-don't use a C-clamp on the piston.
Raise the vehicle and remove the tire. The rear calipers have only one guide pin. Remove this pin and raise the caliper. Remove the old brake pads. Using the special tool compress the caliper piston-the piston will have one or two slots on it. These slots must in the correct position to remount the caliper. Install the new brake pads and slide the caliper back over the rotor and replace the guide pin. If the caliper doesn't slide over the rotor you'll need to reset the slots on the piston. Replace the tires and you're ready to go.

Removal & Installation Front To Remove:

1. Inspect the fluid level in the master cylinder reservoir. Remove fluid from the reservoir until the level is lower then half way between the MAX and MIN levels.
2. Remove the tire and wheel assembly.
3. Install 2 wheel nuts to secure the rotor on the hub.
4. Remove the bottom brake caliper pin bolt.
5. Pivot the brake caliper body upward and secure out of the way. Do NOT disconnect the hydraulic brake flexible hose from the caliper.
6. Compress the piston back into the bore using a C-clamp. Figure of brake assembly with caliper raised showing brake pads in mounting bracket
   
   
7. Remove the inboard and outboard brake pads from the brake caliper bracket.

To Install:

1. Install the brake pad retainers and both brake pads into the caliper bracket.
2. Pivot the brake caliper down over the brake pads and into the brake caliper bracket. Insert the lower brake caliper pin bolt and torque bolt to 70 ft-lb. (95 Nm).
3. Reinstall the tire and wheel assembly.
4. Lower the vehicle.
5. Refill the master cylinder. Pump the brake pedal several times to seat the pads against the rotor.
6. Check the master cylinder level and add fluid as necessary.

Rear To Remove:
Rear disc pads R&I

1. Inspect the fluid level in the master cylinder reservoir. Remove fluid from the reservoir until the level is lower then half way between the MAX and MIN levels.
2. Remove the tire and wheel assembly.
3. Install 2 wheel nuts to secure the rotor on the hub.
4. Remove the upper caliper mounting bolt.
5. Pivot the caliper down to access the pads.
6. Remove the inboard and outboard pads from the caliper bracket.
7. Remove the brake pad clips from the caliper bracket.
8. Compress the piston back into the bore using a C-clamp and the old inner pad.

To Install:

1. Install new brake clips in the caliper bracket.
2. Install the inboard and outboard pads in the caliper bracket.
3. Pivot the caliper up over the pads.
4. Reinstall the upper mounting bolt and tighten to 32 ft. lbs. (44 Nm).
5. Remove the 2 wheel nuts securing the rotor.
6. Reinstall the tire and wheel assembly.
7. Refill the master cylinder. Pump the brake pedal several times to seat the pads against the rotor.
8. Check the master cylinder level and add fluid as necessary.

No do not use a c clamp to press the rotor back in unless you plan on breaking your clamp !!!! On that particular model of (Tiburon) the calipers screw back in.

Steps to replace front brake rotors and pads:

Safley jack up vehicle.
support vehicle on safety stands
remove front wheels
Remove 2 bolts holding the caliper to the caliper support.
remove caliper
remove old brake pads
remove 2 bolts holding caliper support to the spindle
remove rotor, might need a good whack with a hammer to loosen rust bond, also might have a locking ring on one lug stud
sand any and all rust from wheel hub
apply a liberal coating of antisiezing compound.
replace rotor and one lug nut to hold rotor steady
replace caliper support
replace new brake pads making sure squeel sensors are on inside upper corner, also make sure to apply caliper grease to caliper slides and pad sliding surfaces push caliper piston back.
replace caliper
replace wheels and torque to specs
lower vehicle
pump pedal
road test listening for any noises.

PS. these are generic instructions that are very basic, performing a brake job is a very precise and careful job. remember this syetem is responcible for stoping your vehicle at 65mph. this is not a job to attemp if you do not have a good grasp of mechanical applications. One mistake could cause you your life or injurt to your persons or someone else. if you are not comfortable undertaking this task please consult a professional.

please feel free to ask any additional questions you might have.

Disk Brakes - remove two 14mm bolts which mount the caliper to the rear hub assy. Remove the caliper. Remove the phillips screw which holds the rotor to the hub. Machine the rotor and reinstall on the hub & reinstall the phillips screw. Reinstall the caliper and remove one of the caliper hinge pin (sliding pin) 14mm bolts. Flip the caliper out of the way and replace the pads and anti-rattle springs. Recompress the caliper piston all the way back into its cylinder. Flip the caliper back into position and reinstall the 14mm bolts. Of course, you need to purchase the replacement pads and w/anti-rattle springs.

For a wrench or for the acctual bolt size.
To remove front pads..you need 8mm allen socket to pull the caliper guide pins, then 17 or 18mm..To remove rear pads...you need 13mm socket for lock bolt on guide pins and 15mm open end wrench (thin section to hold guide pin while you remove lock bolts..I ground down a spare wrench). You DO NOT have to remove rear carriers to change rotors..just remove lock screw and angle rotor out. The B5 Passats don't have the electronic parking brake so you don't need VAG Com to change pads.
Installation tips:
Clean and regrease the guide pins with "synthetic caliper grease"
Rear lock bolts come with preapplied thread locker and "are not to be reused"..I just wire brush the threads and use some Loctite Blue on em. I smear just a little antisieze on the inside bore of the rotors and on the lock screw threads to prevent corrosion and make next rotor change ez. Torques:
Front caliper guide pins:18 ft lb
Front carrier bolts: 89 ft lb
Rear guide pin lock bolts:26 ft lb
Wheel lugs: 89 ft lb

It's fairly easy and the tool cost less than $10 at most auto parts stores, so why rent it? As for instructions...here you go:

- "Loosen" lug nuts.
- Jack the car up. Support with jack stand(s).
- Remove previously loosened lugs. Remove tire.
- Remove bottom caliper bolt
- Loosen, but do not remove top caliper bolt
- Caliper should now "swing" open from bottom up
- Remove old pads. They should slide right out.
- Spray in some "Brake Kleen" to clear out all that brake dust/gunk and wipe it down. You may want to place a rag or something to catch the brake kleen run off.
- Inspect your old pads for "uneven wear". This will save you tons of time later if you have a bad rotor or stuck piston that has been causing uneven wear or gouges.
- If they are worn evenly, proceed to compress the piston back into the caliper with your tool.

Some tools attach to a socket end, this enables you to ratchet the piston back "IN" to it's original position. Either way you can only turn clockwise regardless of the tool. It will be tough, but not impossible. You should encounter tough but "smooth" resistance. Both rear pistons should feel similar in resistance, if not you may have a stuck piston. You'll know though ;)

-Once completely compressed, slide in your new pads and bring the caliper back down into po-si-tion. NOTE: If you removed both TOP and BOTTOM caliper bolts it may be tricky lining them back up with a new "full" brake pad, but be persistent and wiggle those bolts back in place. DO NOT FORCE OR CROSS-THREAD ANY BOLT. WD40 should help.
- Once the new pads are on and the caliper is back in place, make sure to break them in nice and easy with slow consistent stops for the first 50 miles or so.
-The pads will touch the rotor, but that's normal and you should still be able to turn the rotor with some resistance. Once the tire is mounted, it should turn alot smoother.

Hope this helps.