Brakes Smokin' Hot after service 730deg!

[Toolaa]

Hey guys its been a while since I've posted. The B6 has been running well but I've got a weird problem with the 2005 B5.5 Passat.

On Sunday changed rear rotors and pads along with doing a full bleed on all four wheels.

After getting everything back together and taking a quick test drive I have ABS and EPC lights on dash. Pedal feels real stiff and front brakes are smoking. Rotors are smoking hot. 730 deg and calipers are 513 when Measured with my inferred thermometer.

Remember I didn't even change or mess with the front except to bleed the lines.

Back brakes seem hot too 335 rotors and 262 deg calipers but not smoking.

Pulled codes with VCDS and only have 1 error

01435 - Brake Pressure Sensor 1 (G201)
35-10 - - - Intermittent

After everything cooled down I lifted up the front and rear and the wheels spin freely. Checked again for air in the lines and bled a bit more fluid through but didn't find any obvious issues.

Went test drive again and ABS and EPC light go off before I reach then end of my cul de sac and things seem fine. No codes either. I decide to drive a bit and after about 1/2 mile I get ABS and EPC lights again and pedal is rock hard. By the time I get back home the front brakes are smoking again. And this time I didn't even make any hard test stops. Pulled codes again and have same error as before.

I am totally clueless here?






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[Toolaa]

Just got home from work and did another quick test drive. The brakes are definitely dragging on the rotors. When i got back from the test drive I jacked up rear drivers side and i could barely turn the tire.

I hooked up VCDS again to see if I could see anything unusual and I see in measuring block 003 the pressure is 0.33 bar even with my foot off the pedal. I compared this to the Audi and i'm getting -0.2 bar with no pressure on the pedal. So somehow I'm managed to over-pressurize the brake system.

I did use the Motive power bleeder but only at 15psi to bleed the brakes so I' still scratching my head looking for any suggestions.


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[Toolaa]

Finally Solved. Didn't have time to post earlier.

There is a plastic panel above the drivers foot well to protect the wiring below the instrument panel. Somehow this plastic panel moved and the tongue of plastic normally positioned between the two pedals was pressing on the arm of the brake pedal. It was pushing just enough to keep the pads touching the rotors.




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