AUDI A4 1996 B5 / 1.G Front Calipers Workshop Manual

47-2


Teves/Ate front brake calipers,
servicing Note:

Install only the complete repair kit when
performing servicing work.
New brake calipers are filled with brake fluid
and pre-bled.
Apply a thin coating of assembly paste to brake
cylinders, pistons and seals.
1 -
Caps
Insert into plastic bushing
2 -
Guide pin 25 Nm (18 ft lb)
3 -
Bleeder valve Apply a thin coating of assembly paste to
the threads before installing
4 -
Dust cap Install on bleeder valve
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47-3


CAUTION! 5 -
Brake caliper housing
6 -
Retaining spring
Insert the two ends into the holes of the
brake caliper housing

Once the spring ends are seated in the holes,
press the retaining spring under the brake
carrier.
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.
7 -
Plastic bushing
Insert into brake caliper housing
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47-4


8 -
Brake carrier
Bolt to brake caliper housing
9 -
Seal
10 -
Piston Apply thin coat of assembly paste before
installing Piston diameter: 57 mm (2.24 in.)
11 -
Protective seal Do not damage when installing the piston
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47-5

Teves/Ate front brake caliper piston,
removing and installing


Special tools and equipment
3409 wedge

Removing

WARNING! - Force piston out of brake caliper housing using compressed air.
Risk of accident! Apply pressure gradually. Guard against the
sudden release of the piston. Place a wooden block into the recess of the caliper housing to
catch the piston so it is not damaged. Always wear safety glasses when carrying out this step.

Note:
When removing make sure that the surface of the cylinder is not
damaged. - Using 3409 wedge, remove seal.
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47-6

Installing

CAUTION!
Part numbers are listed here for reference only. Always check with
your Parts department for the latest information. - Place protective seal with outer sealing lip on piston.
- Clean surfaces of piston and seal using methylated spirits only, then
dry.
- Apply thin coat of assembly paste, part number G 052 150 A2 to piston
and seal before installing.

Note:
Hold the piston in front of the caliper housing for this procedure. - Using 3409 wedge, insert inner sealing lip into cylinder groove.
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47-7


Note:
The outer sealing lip of the protective seal will then locate in the piston
groove. - Press piston into brake caliper housing using piston resetting tool.
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11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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pair&id=AUDI.B5.SU03.47.2