First of all compliments for the wonderfull tutorial (
http://www.a4mods.com/index.php?page=webcontent/pages/caliperrebuild.html&category=2and good pictures!
Very helpful for me as I am rebuilding the calipers of my Allroad 2001 that has the same model Lucas double piston calipers.
I would describe myself as a experienced amateur of 20 years +, who luckily has a number of friends who are professional mechanics.
As I came past you post when I was looking for information, just thought it would be nice to share my experience and additions.
I have been looking everywhere for the rubber sleeve/dust boot part for the middle guide pin for my Audi Allroad 2001 front caliper.
I damaged one when I was cleaning the caliper for a complete rebuild. Assuming it would be simple to replace... What a mistake to make...
Currently I used automotive rubber seal (for fixing rubber sleeves like this) to repair the little tear I made. And that’s OK for now (I Hope).
The rubber is not available at Lucas/TRW nor the Audi dealer.
I know because I called the TRW/Lucas factory in Germany a few weeks ago.
All brake-recondition shops in Holland who specialize in the impossible/old/hard to get brake jobs I spoke too, told me to give them a call once I have found a alternative solution for this sleeve.... They don’t recondition the unit if the rubber is damaged....
I followed your advise to break the caliper into 3 parts to clean it up for repainting (the only way to get into every corner to clean out all the rust and dirt).
I left the aluminum part containing the pistons connected to the car and cleaned it there.
The other 2 parts I disconnected using a air wrench.
In addition to your tutorial I would like to add::
1. Removal of the rubber sleeve/ dust boot:
You suggest: “
Use a flathead screwdriver or something similar and pry it up from the bottom. Slowly work your way around the boot being careful not to pry against the rubber.”My experience: CAREFULLY put a thin (!) flathead screwdriver underneath the rubber & ring (the rubber has a steel ring molded into it) at a 45 degrees angle and gently tap it with a hammer. The ring is 'clicked' into place. And will come loose after 1 gentle tap. Use a THIN flathead. You don’t need to use it as a lever!
2. Refitting the rubber sleeve/dus boot:
You suggest:
“As before, the boot has a metal retaining ring around it. In order to get it in place you can just use a flathead screwdriver to work around the edges from the inside of the boot.
Also, you could use a socket to push it into place.”My Experience: Doing it your way makes putting on the dust boot the other end very difficult. There just isn’t enough space. And using a small screwdriver or the like to try to push it into place will damage the rubber.
My suggestion is probably how they do it in the factory: Clean up the ring and where it is going to sit.
Then the rubber sleeve in place on the other end (other side then were the ring is).
Then apply grease (don’t use copper grease , it messes with your ABS, but the white ceramic paste).
Then put the 2 parts together and just compress them together. You'll hear 'click' and the ring + rubber is in place.
3. Golden tip:
Buy a reconditioned set from US company Cardone. For about 160 USD (including 50 USD for the exchange unit!) it is a steal... Esp. if you count the hours and parts. In Holland it’s not so cheap unfortunately.
4. When pushing back the brake pads
When you are removing the brake pads, do not push the oil back into the reservoir. Instead open the bleeder valve and let the brake oil flow back that way. If you do not, you might damage the ABS system. Why run the risk?
5. Cleaning:
After playing around with all kinds of (kitchen/industrial) cleaning product to clean up the calipers, I found that a mechanical wire brush works 10 times better the anything else! I use big ones on the angle grinder, a workbench mounted wire brush and 2 smaller ones on a drill. And still I had to use a handheld one for some bits... Plus an old screwdriver for the last corners. Hence my tip 3.
On the Alu part I used some very fine grit (600) waterproof sandpaper to smoothen out the surface. Use turpentine/petrol or as a lubricant instead of water.
Use a chemical de-ruster to really clean out the last rust on the metal parts. Sandblasting dirt tends to go everywhere. And you don’t want that inside your brake caliper.
Clean out with large amounts of brake cleaner.
6. Painting the calipers
I painted all steel parts with black Hammerite and the Aluminum parts with a clear varnish.
After looking at many other, much more expensive, solutions I realized that if a rally driver I read about does it this way, then so can I. After all my brakes will never be as hot as his. Ever.
I have done this before on other calipers. And after many years still not paint falling off or rust.
7. These calipers were fitted on many more Audi and VW models then just the S4/A4.
Also on A6/A8 etc. Source: Cardone.com.
In case you are looking for secondhand parts...
Year Make Model Trim Engine
2005 Audi Allroad Quattro Base Wagon 4-Door 2.7L 2671CC V6 GAS DOHC Turbocharged
2005 Audi Allroad Quattro Base Wagon 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2005 Volkswagen Passat GL Sedan 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2005 Volkswagen Passat GL TDI Sedan 4-Door 2.0L 1967CC 120Cu. In. l4 DIESEL SOHC Turbocharged
2005 Volkswagen Passat GL Wagon 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2005 Volkswagen Passat GLS 4 Motion Sedan 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2005 Volkswagen Passat GLS 4 Motion Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2005 Volkswagen Passat GLS 4 Motion Wagon 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2005 Volkswagen Passat GLS 4 Motion Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2005 Volkswagen Passat GLS Sedan 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2005 Volkswagen Passat GLS Sedan 4-Door 2.0L 1967CC 120Cu. In. l4 DIESEL SOHC Turbocharged
2005 Volkswagen Passat GLS Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2005 Volkswagen Passat GLS Wagon 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2005 Volkswagen Passat GLS Wagon 4-Door 2.0L 1967CC 120Cu. In. l4 DIESEL SOHC Turbocharged
2005 Volkswagen Passat GLS Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2005 Volkswagen Passat GLX 4 Motion Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2005 Volkswagen Passat GLX 4 Motion Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2005 Volkswagen Passat GLX Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2005 Volkswagen Passat GLX Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2004 Audi A6 Base Sedan 4-Door 3.0L 2976CC V6 GAS DOHC Naturally Aspirated
2004 Audi A6 Quattro Avant Wagon 4-Door 3.0L 2976CC V6 GAS DOHC Naturally Aspirated
2004 Audi A6 Quattro Base Sedan 4-Door 2.7L 2671CC V6 GAS DOHC Turbocharged
2004 Audi A6 Quattro Base Sedan 4-Door 3.0L 2976CC V6 GAS DOHC Naturally Aspirated
2004 Audi A6 Quattro Base Sedan 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2004 Audi Allroad Quattro Base Wagon 4-Door 2.7L 2671CC V6 GAS DOHC Turbocharged
2004 Audi Allroad Quattro Base Wagon 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2004 Volkswagen Passat GL Sedan 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2004 Volkswagen Passat GL Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2004 Volkswagen Passat GL Wagon 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2004 Volkswagen Passat GL Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2004 Volkswagen Passat GLS 4 Motion Sedan 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2004 Volkswagen Passat GLS 4 Motion Wagon 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2004 Volkswagen Passat GLS Sedan 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2004 Volkswagen Passat GLS Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2004 Volkswagen Passat GLS Wagon 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2004 Volkswagen Passat GLS Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2004 Volkswagen Passat GLX 4 Motion Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2004 Volkswagen Passat GLX 4 Motion Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2004 Volkswagen Passat GLX Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2004 Volkswagen Passat GLX Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2004 Volkswagen Passat W8 Sedan 4-Door 4.0L 3998CC 244Cu. In. W8 GAS DOHC Naturally Aspirated
2004 Volkswagen Passat W8 Wagon 4-Door 4.0L 3998CC 244Cu. In. W8 GAS DOHC Naturally Aspirated
2003 Audi A6 Base Sedan 4-Door 3.0L 2976CC V6 GAS DOHC Naturally Aspirated
2003 Audi A6 Quattro Avant Wagon 4-Door 3.0L 2976CC V6 GAS DOHC Naturally Aspirated
2003 Audi A6 Quattro Base Sedan 4-Door 2.7L 2671CC V6 GAS DOHC Turbocharged
2003 Audi A6 Quattro Base Sedan 4-Door 3.0L 2976CC V6 GAS DOHC Naturally Aspirated
2003 Audi A6 Quattro Base Sedan 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2003 Audi A8 Quattro Base Sedan 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2003 Audi A8 Quattro L Sedan 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2003 Audi Allroad Quattro Base Wagon 4-Door 2.7L 2671CC V6 GAS DOHC Turbocharged
2003 Audi S6 Avant Wagon 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2003 Volkswagen Passat GL Sedan 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2003 Volkswagen Passat GL Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2003 Volkswagen Passat GL Wagon 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2003 Volkswagen Passat GL Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2003 Volkswagen Passat GLS Sedan 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2003 Volkswagen Passat GLS Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2003 Volkswagen Passat GLS Wagon 4-Door 1.8L 1781CC l4 GAS DOHC Turbocharged
2003 Volkswagen Passat GLS Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2003 Volkswagen Passat GLX 4 Motion Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2003 Volkswagen Passat GLX 4 Motion Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2003 Volkswagen Passat GLX Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2003 Volkswagen Passat GLX Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2003 Volkswagen Passat W8 Sedan 4-Door 4.0L 3998CC 244Cu. In. W8 GAS DOHC Naturally Aspirated
2003 Volkswagen Passat W8 Wagon 4-Door 4.0L 3998CC 244Cu. In. W8 GAS DOHC Naturally Aspirated
2002 Audi A6 Base Sedan 4-Door 3.0L 2976CC V6 GAS DOHC Naturally Aspirated
2002 Audi A6 Quattro Avant Wagon 4-Door 3.0L 2976CC V6 GAS DOHC Naturally Aspirated
2002 Audi A6 Quattro Base Sedan 4-Door 2.7L 2671CC V6 GAS DOHC Turbocharged
2002 Audi A6 Quattro Base Sedan 4-Door 3.0L 2976CC V6 GAS DOHC Naturally Aspirated
2002 Audi A6 Quattro Base Sedan 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2002 Audi A8 Quattro Base Sedan 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2002 Audi A8 Quattro L Sedan 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2002 Audi Allroad Quattro Base Wagon 4-Door 2.7L 2671CC V6 GAS DOHC Turbocharged
2002 Audi S6 Avant Wagon 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2002 Volkswagen Passat GLS 4 Motion Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2002 Volkswagen Passat GLS 4 Motion Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2002 Volkswagen Passat GLX 4 Motion Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2002 Volkswagen Passat GLX 4 Motion Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2002 Volkswagen Passat GLX Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2002 Volkswagen Passat GLX Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2002 Volkswagen Passat W8 Sedan 4-Door 4.0L 3999CC 244Cu. In. W8 GAS DOHC Naturally Aspirated
2002 Volkswagen Passat W8 Wagon 4-Door 4.0L 3999CC 244Cu. In. W8 GAS DOHC Naturally Aspirated
2001 Audi A6 Quattro Avant Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2001 Audi A6 Quattro Base Sedan 4-Door 2.7L 2671CC V6 GAS DOHC Turbocharged
2001 Audi A6 Quattro Base Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2001 Audi A6 Quattro Base Sedan 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2001 Audi A8 Quattro Base Sedan 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2001 Audi A8 Quattro L Sedan 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2001 Audi Allroad Quattro Base Wagon 4-Door 2.7L 2671CC V6 GAS DOHC Turbocharged
2001 Audi S4 Avant Wagon 4-Door 2.7L 2671CC V6 GAS DOHC Turbocharged
2001 Audi S4 Base Sedan 4-Door 2.7L 2671CC V6 GAS DOHC Turbocharged
2000 Audi A6 Quattro Avant Wagon 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2000 Audi A6 Quattro Base Sedan 4-Door 2.7L 2671CC V6 GAS DOHC Turbocharged
2000 Audi A6 Quattro Base Sedan 4-Door 2.8L 2771CC V6 GAS DOHC Naturally Aspirated
2000 Audi A6 Quattro Base Sedan 4-Door 4.2L 4172CC V8 GAS DOHC Naturally Aspirated
2000 Audi S4 Base Sedan 4-Door 2.7L 2671CC V6 GAS DOHC Turbocharged
Good luck with your forum and Audi's.
Best regards from Holland!
