AUDI A4 1996 B5 / 1.G Rear Brake Service Workshop Manual

46-20


Rear brakes, servicing Rear brakes with automatic parking brake
adjusters
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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46-21


Note:

Install only the complete repair kit.
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).
1 -
Self-locking bolt
Always replace35 Nm (26 ft lb)Counter-hold guide pin when loosening
and tightening
2 -
Brake pads Always replace as a set on both wheels of
an axle Removing and installing page 46
-24
Brake pad thickness when new: 12 mm
(0.47 in.) Brake pad wear limit (friction material): 2
mm (0.08 in.) Brake pad wear limit (including backing
plate): 7 mm (0.28 in.)
3 -
Ribbed bolt For vehicles with front wheel drive95 Nm (70 ft lb)
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46-22


Note:
Until changing over to ribbed bolts, the remaining
socket-head bolts should be used. Tightening
torque for the socket-head bolt is 60 Nm (44 ft lb).
3 -
Socket-head bolt
For vehicles with all wheel drive60 Nm (44 ft lb)
4 -
Brake carrier with guide pins and
protective caps Supplied as a pre-assembled replacement
part with adequate amount of grease on
guide pins If the caps or guide pins are damaged,
install repair kit Use quantity of grease from repair kit for
greasing guide pins
5 -
Ribbed bolt For vehicles with front wheel drive95 Nm (70 ft lb)
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46-23


Note:
Until changing over to ribbed bolts, the remaining
socket-head bolts should be used. Tightening
torque for the socket-head bolt is 60 Nm (44 ft lb).
5 -
Socket-head bolt
For vehicles with all wheel drive60 Nm (44 ft lb)
6 -
Brake disc Always replace as a set on both wheels of
an axle To remove, first unbolt brake caliperResurface evenly on both sides starting
from thickness when new Brake disc diameter: 245 mm (9.65 in.)Brake disc thickness: 10 mm (0.39 in.)Wear limit: 8 mm (0.31 in.)
7 -
Brake caliper housing Do not disconnect brake hose when
replacing brake pads Servicing caliper 47
-13
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46-24

Rear 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.

Installing - Unbolt brake caliper housing.
- Remove brake pads.

Note: - Screw piston in by turning threaded spindle of special tool 3272 to
right.
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Insert special tool 3272 so that the collar is positioned ahead of the piston.
WARNING!
Brake fluid is poisonous and must NEVER be removed by siphoning
with your mouth.
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46-25

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.

CAUTION!
The repair kit contains four self-locking hex bolts which must always
be installed.
Note:
Depress the brake pedal firmly several times while the car is stationary so
that the brake pads adjust to their normal operating positions. - Install brake pads in brake carrier (arrows).
- Bolt on brake caliper housing.
Tightening torque: 35 Nm (26 ft lb)
- Install wheels and tighten wheel bolts.
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Tightening torque: 120 Nm (89 ft lb)
- Check brake fluid level and top up if necessary.
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46-26

Rear brake pads on front-wheel-drive
vehicles with aluminum rear brake
calipers, removing and installing


Special tools and equipment
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!
3272 reset and screwout tool 3272/1 support plate
- Remove wheels.

- Counter-hold guide pins and remove self locking bolts from brake
caliper housing.
- Remove brake pads.
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46-27

Installing

WARNING!

Brake fluid is poisonous and must NEVER be
removed by siphoning with your mouth.

CAUTION!

Before pushing back the piston, siphon
some of the brake fluid out of the brake fluid
reservoir. Otherwise, particularly if reservoir
has been topped off, fluid will overflow and
cause damage.
To siphon brake fluid, always use a bleeder
bottle which is only used to siphon brake
fluid.

- Screw piston inward as far as it will go by turning threaded spindle
(arrow) clockwise and knurled section counterclockwise.
Pa
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