1996 AUDI A4 brake fluid

46-1


Front brakes, servicing Teves/Ate front brakes

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.
Pa
ge 1 of 22 Front brakes, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU03.46.1

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.
Pa
ge 9 of 22 Front brakes, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU03.46.1

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.
Pa
ge 10 of 22 Front brakes, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU03.46.1

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.
Pa
ge 12 of 22 Front brakes, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU03.46.1

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.
Pa
ge 13 of 22 Front brakes, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU03.46.1

46-16

Double piston front caliper brake pads,
removing and installing


Removing

Note:
If brake pads are to be re-used, mark installed
positions when removing. Re-install at the same
point, otherwise the car may pull to one side!

- Raise vehicle.

- Remove wheels.

WARNING!
Brake fluid is poisonous and must never be removed by siphoning
with your mouth.
CAUTION! - Secure brake disc with wheel bolt (left arrow).
-
Remove both Torx bolts for outer brake pads (right arrows).
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.
Pa
ge 18 of 22 Front brakes, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU03.46.1

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.
Pa
ge 19 of 22 Front brakes, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU03.46.1

46-19


CAUTION!
The repair kit contains four self-locking Torx bolts which must
always be installed.
Note:
After replacing brake pads depress the brake pedal firmly several times
while the car is stationary so that the brake pads adjust to their normal
operating positions. - Press floating frame out as far as stop.
- Remove protective sheet from back of outer brake pads.

Note:
Make sure wheels do not hang on brake calipers when they are installed.
The brake pads could be pushed out of the caliper frame. -
Install Torx bolts (right arrows) from repair kit into floating frame to
secure outer brake pads in position. Tightening torque: 25 Nm (18 ft lb)
- Remove wheel bolt from wheel hub.
- Install wheels and tighten wheel bolts.
Tightening torque: 120 Nm (89 ft lb)
- Check brake fluid level and top up if necessary.
Pa
ge 22 of 22 Front brakes, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU03.46.1