My Passat TDI has done just under 200k and just started the dreaded front brake clunk a few weeks ago. This would only happen at slow speeds and the car also made a lot rattling and banging when going over small bumps.
After doing some inspection I found my OS lower rear control arm had slight play in the bush so I changed this thinking problem solved.
Wrong!
Next I checked the brake pads after reading about these becoming loose in the carriers. I had only just changed my pads and discs a month early using GSF cheap pads (costing £23.50). When I removed the caliper I found the outside pad had about 1mm play up and down and the inside pad clips had become loose in the piston. I used a tip from the Passatworld forum and hit top and bottom of all my pads using a center punch to swell it making it fit the carrier better. All was good for a week till the clunking began again
Reading some other forums again for advice I had a choice of changing all the front bushing or try some better pads, so Friday I bought some Bosch pads from Euro car parts (costing £32) and job done! No clunk and a massive improvement in braking. The pads I had removed had now come apart from the anti rattle plates and had also worked themselves loose in the carriers again.
So I would now advise anyone else to spend a litte bit more on pads and not buy cheap poo.
Hope this helps others before they change all there front bushes and waste money.
