1996 AUDI A4 Front Brake Service Workshop Manual

46-8


CAUTION!
Installing - Remove both guide pins from brake caliper.
- Remove brake caliper housing and secure to body.
Do not loosen brake hose or lines.Secure the brake caliper with a piece of wire in order to relieve the
stress on the brake hose. Do not allow the caliper to hang by the brake hose.
- Remove outer brake pad from brake carrier.
- Pull inner brake pad (with expanding spring) out of brake caliper piston.

WARNING!
Brake fluid is poisonous and must never be removed by siphoning
with your mouth. - Push piston back into brake caliper housing.
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46-9

CAUTION!

Extract part of the brake fluid from the brake
fluid reservoir before pushing back the
pistons.
If this is not done, particularly if the brake
fluid has been topped up in the meantime,
brake fluid may flow out and cause damage.
Use the bleeder bottle or a plastic bottle,
which is used only for brake fluid, for
extracting the fluid.
The inner brake pad (with expanding spring)
is marked with an arrow that must point in
the direction of rotor rotation when the
vehicle is moving forward. Incorrect
installation can result in excessive noise.

- Install inner brake pad (with expanding spring) in brake caliper piston
(left arrow). Arrow marked on pad must point in direction of rotor
rotation when vehicle is moving forward.
- Remove protective sheet from backing plate for outer brake pad.
- Install outer brake pad into brake carrier (right arrow).
- Bolt brake caliper housing to brake carrier using two guide pins.
Tightening torque: 25 Nm (18 ft lb)
- Install both caps.
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- Insert retaining spring into brake caliper housing.
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46-10

- Once spring ends are seated in holes, press
retaining spring under brake carrier.

CAUTION!

If the spring is not installed correctly, the
outer brake pad alignment mechanism will
not be able to compensate for wear, and
increased brake pedal travel will result.

Note:
Depress the brake pedal firmly several times
while the car is stationary so that the brake pads
adjust to their normal operating positions.

- Check brake fluid level and top up if
necessary.
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46-11


Double piston front brake calipers,
servicing

WARNING!

Do not re-use fasteners that are worn or
deformed in normal use.
Some fasteners are designed to be used only
once, and are unreliable and may fail if used
a second time. This includes, but is not
limited to, nuts, bolts, washers, circlips and
cotter pins. Always follow recommendations
in this manual-replace these fasteners with
new parts where indicated, and any other
time it is deemed necessary by inspection.
To siphon brake fluid, always use a bleeder
bottle which is only used to siphon brake
fluid.
Brake fluid is poisonous and must NEVER be
removed by siphoning with your mouth.
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46-12


Note:

Install complete repair kit.
After installing the brake pads, depress the
brake pedal firmly several times before moving
the vehicle to properly seat the brake pads in
their normal operating position.
The brakes can be tested on a commercial
brake dynamometer provided the speed of the
two dynamometer drive rollers is not more than
5.5 km/h (3.3 mph).
Tightening torque for the brake lines is 15 Nm
(11 ft lb).
1 -
Torx bolt
Always replace25 Nm (18 ft lb)Remove and install using commercially
available Torx socket T40 Bolts are included in the repair kit for the
brake pads
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46-13


CAUTION! 2 -
Brake disc
Always replace as a set on both wheels of
an axle Ensure adequate thicknessTo remove, first unbolt brake caliper
Internally ventilated brake discDiameter: 245 mm (9.65 in.)Thickness: 30 mm (1.18 in.)Wear limit: 28 mm (1.10 in.)
3 -
Brake caliper

Do not allow the caliper to hang by the brake
hose. The unsupported weight can stretch
and damage the hose.
Secure the brake caliper with a piece of wire
in order to relieve the stress on the brake
hose.
With the exception of replacing brake pads
page 46
-16
and servicing front brake calipers
page 46
-11
, no further repairs may be
performed to the brake caliper
4 -
Clamping spring
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46-14


5 -
Ribbed bolt
200 Nm (148 ft lb)Clean ribbing if re-using
6 -
Brake line 15 Nm (11 ft lb)
7 -
Retaining spring
8 -
Harness connector Only on models with wear indicators
9 -
Brake hose Do not disconnect the brake hose from the
caliper when replacing brake pads.
10 -
Bolt 25 Nm (18 ft lb)
11 -
Bracket Bolt to brake caliper housingInstall harness connector for brake pad
wear indicator
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