1996 AUDI A4 wheel

46-3


3 -
Guide pin
25 Nm (18 ft lb)
4 -
Brake line 15 Nm (11 ft lb)Install into caliper housingWhen tightening to brake hose, counter
hold on brake hose hex Make sure lugs are properly seated in
retainer grooves
5 -
Brake caliper housing Unbolt from brake carrier for replacing
brake pads Servicing brake caliper 47
-2
6 -
Ribbed bolt
125 Nm (92 ft lb)Clean ribbing if re-using
7 -
Brake carrier Bolt to wheel bearing housing
Pa
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46-4


CAUTION!
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.
Note:
Before installing new brake pads, thoroughly clean
the brake calipers (free of grease). Pay particular
attention to removing any adhesive residue from
the outer brake pad contact surfaces. 8 -
Brake pads

Outer pads have an adhesive with a protective
sheet on the backing plate; remove this sheet
before installing
Different versions parts catalogue microfiche Always replace as a set on both wheels of an
axle
Removing and installing page 46
-7
Brake pad wear limit (friction material): 2 mm
(0.08 in.)
Brake pad wear limit (including backing plate): 7
mm (0.28 in.)
Pa
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46-5


CAUTION!
If the spring is not installed correctly, the outer
brake pad alignment mechanism will not be able
to compensate for wear, and increased pedal
travel will result. 9 -
Retaining spring
Insert into both holes in brake caliper
housing Once spring ends are seated in holes,
press retaining spring under brake carrier
10 -
Brake disc Always replace as a set on both wheels of
an axle To remove, first unbolt caliperResurface evenly on both sides starting
from thickness when new
Internally ventilated brake disc:Diameter: 288 mm (11.34 in.)Thickness: 25 mm (0.984 in.)Wear limit: 23 mm (0.906 in.)
Non-ventilated brake disc:Diameter: 288 mm (11.34 in.)
Pa
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46-7

Teves/Ate brake pads, removing and
installing


Removing

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

- Raise vehicle.

- Remove wheels.

- Use screwdriver to pry brake pad retaining spring out of brake caliper
housing, and remove spring.

- Remove top and bottom caps (arrows).
Pa
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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
Pa
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46-15


12 -
Harness holder
Only on models with wear indicatorsInstall harness for brake pad wear indicator
into harness holder
13 -
Brake pads Always replace as a set on both wheels of
an axle Different left and right sidesRemoving and installing page 46
-16
With wear indicator
Once wear limit is reached (3 mm, 0.12
in.), warning light in instrument panel
comes on Brake pad thickness: 14 mm (0.55 in.)Outer pads have an adhesive with a
protective sheet on the backing plate;
remove this sheet before installing
Pa
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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
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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
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11/19/2002 htt
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pair&id=AUDI.B5.SU03.46.1