As mentioned above you can replace the soft goods in your caliper with a kit. Another option is to buy a rebuilt caliper. They are not very expensive. I bought Raybestos recently. Given the age of your vehicle that's what I would do.
It's a known problem with knocking brakes on the off rear of B6 passats. To fix, remove the caliper, pull out the top and bottom did pins and half fill with a heavy grease or copper grease into the holes the slide pins slide on, refit and no more noise! Just did mine last week.
The Passat 11.3" ATE 57 calipers are the same physical size as the 11.3" ATE DE 54s that came on 96-99 MKIII VRs. So any wheel that will fit over a MKIII VR 11.3" Girling DE 54 brake caliper should fit over the Passat 11.3" brake caliper.
It takes a larger master cylinder to push more fluid to four pistons. The surface area of all 4 pistons pushing on the disc is slightly larger than OE. A larger (thicker) rotor is being used and I'm not sure how to calculate that into the equation or if that's even important. Regardless if you have the oe mater cylinder using Porsche 4 pot calipers you will have to get a larger master cylinder.
I have an 04 W8, ill say this. Get a BBK from Brembo or someone. The front calipers are way to wide and large for what they would do for a smaller car vs the cost to make them work.
ok so last weekend i did 312mm rotors, porsche boxster calipers and stainless lines. i had g60 brakes previous. i bled them out nooooooo air. drove the car and expected to stand it on it nose. brakes no better than what i had, maybe worse.
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