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Brake System: Removal & Installation Audi A6 C5 facelift

Mechanical - Hydraulic 20 illustrations ~2144 words

Removal & Installation

  1. Raise and support vehicle. Remove wheels. If replacing calipers, disconnect brakeline from caliper, and plug openings. If not replacing calipers, DO NOT disconnect brake line from caliper. Hang brake caliper from body or suspension. Do not allow caliper to hang by brake hose or line.
  2. On all calipers, remove caliper mounting bolts. see scheme 2- see scheme 3. Remove caliper assembly from wheel bearing housing.
  3. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-139121-S24478463152002042500000). Bleed hydraulic brake system. See «BLEEDING BRAKE SYSTEM»(ref-139121-S24915216092002042500000) under BLEEDING BRAKE SYSTEM.

Removal & Installation (FN3)

  1. Raise and support vehicle. Remove front wheels. Secure brake disc with a wheel bolt.
  2. Remove protective caps. see scheme 2 Using a flatbladed tool, pry off brake pad retaining spring from brake caliper housing and remove.
  3. Remove both guide pins from brake caliper. Remove brake caliper housing and support so that the weight of the brake caliper does not burden or damage the brake hose. Remove brake pads from brake caliper housing or from brake carrier.
  4. To install brake pads, press piston back into caliper housing using resetting tool before inserting new brake pads. Before pushing back the piston, draw off brake fluid out of the brake fluid reservoir with a bleeder bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.
  5. Insert brake pad with retaining spring in brake caliper housing. Inner pad (with spring) is marked with an arrow. The arrow must point in the direction of forward rotation of the brake disc when installed. Noise may result from incorrect installation.
  6. Remove protective foil on backing plate of outer brake pad. Install outer brake pad on brake carrier. Install brake caliper housing in brake carrier using both guide pins, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-139121-S24478463152002042500000).
  7. Install both protective caps. Install retaining spring in brake caliper housing. Retaining spring must be pressed under brake carrier after it is inserted in both holes. If the spring is improperly installed, the brake caliper cannot adjust to compensate for wear on the outer brake pad. This will cause the brake pedal travel to increase.
  8. Install wheels and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-139121-S24478463152002042500000). After installing brake pads and before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level, and top off as necessary.

Removal & Installation (FNR-G60)

  1. Raise and support vehicle. Remove front wheels. Secure brake disc with a wheel bolt.
  2. Using screwdriver, pry off brake pad retaining spring from brake caliper housing and remove. see scheme 3 Disconnect brake wear indicator harness connector. Using a flatbladed tool, release harness connector from the holder turning connector by 90 degrees at the same time. Pull connector out upward and unhook the wire.
  3. Detach brake line from bracket. Remove trim cap and unscrew both guide pins and remove from brake caliper. Remove brake caliper housing and lay to one side so that the weight of the brake caliper does not stress or damage the brake hose. Remove brake pads from brake caliper housing or from brake carrier.
  4. To install pads, press piston back into caliper housing using resetting tool. Before pushing back the piston, draw off brake fluid out of the brake fluid reservoir with a bleeder bottle. Otherwise, if reservoir has been topped off, fluid will overflow and cause damage to finish.
  5. Insert brake pad with retaining spring and wear indicator into brake caliper housing. Install outer brake pad onto brake caliper. Insert pads in brake carrier and install together on brake caliper and brake disc. Secure brake carrier to brake caliper housing with both guide pins, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-139121-S24478463152002042500000).
  6. Ensure brake hose is installed without twisting. Install both protective caps. Insert retaining spring into brake caliper housing. Retaining spring must be pressed under brake carrier after it is inserted in both holes. If the spring is improperly installed, the brake caliper cannot adjust to compensate for wear on the outer brake pad. This will cause the brake pedal travel to increase. Attach brake line. Connect harness connector for wear indicator and engage line in dust cap and trim cap.
  7. Install wheels and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-139121-S24478463152002042500000).
  8. After installing brake pads and before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level, and top off as necessary.

Scheme 10

Scheme 10: Removal (HP2, Aluminum Caliper)
Scheme 10: Removal (HP2, Aluminum Caliper)

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13
  1. Raise and support vehicle. Remove wheels. Install one wheel bolt to secure brake disc.
  2. Disconnect connector for brake pad wear indicator. (Scheme 10) Disengage connector from bracket using a screwdriver and simultaneously turn connector 90 degrees. Lift connector up and out and disengage wire.
  3. Press upper and lower spring tensioner out of locking mechanism using pliers. Slide spring to side. (Scheme 11)
  4. Press piston back into brake caliper housing. To do this, insert floating frame using a screwdriver and press powerfully outward.
  5. Use screwdriver to press outer brake pads off brake caliper. (Scheme 12)
  6. Press floating frame in direction of arrow until stop. (Scheme 13) Carefully press brake pads out of piston and remove brake caliper housing.

Scheme 14

Scheme 14: Installation (HP2, Aluminum Caliper)
Scheme 14: Installation (HP2, Aluminum Caliper)
  1. Clean brake caliper housing thoroughly before installing new brake pads. Be especially careful to remove any residual adhesive foil, left by outer brake pads.
  2. Insert lower and upper brake pads in piston. Be sure protrusions on backing plates are securely installed in brake piston. Do not damage protective caps when installing brake pads. (Scheme 14)
  3. Press floating frame caliper outward until it contacts stop. (Scheme 15)
  4. Install upper and lower tension (anti-rattle) springs in correct position. see scheme 4and (Scheme 11).
  5. Remove wheel bolt from wheel hub. When installing wheels, ensure rim flange does not rest on brake caliper. This could push pads out of position.
  6. After installing brake pads and before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level, and top off as necessary.

Scheme 15

Scheme 15: Removal & Installation (Brembo)
Scheme 15: Removal & Installation (Brembo)
  1. Raise and support vehicle. Remove wheels. Install one wheel bolt to secure brake disc.
  2. For RS6, remove damper bracket bolts and remove bracket. On all models, disconnect connector for brake pad wear indicator. (Scheme 16) Disengage connector from bracket using a screwdriver and simultaneously turn connector 90 degrees. Remove lower half of connector out of holder.
  3. Drive out pad retaining pins (arrows). Remove anti-rattle clips.
  4. Press off the brake pads from the brake disc and remove pads from the brake caliper housing.
  5. Press piston back. Insert brake pads into brake caliper housing. The brake pads are directional, note the markings on the damping panel. Install pad retaining springs. Press retaining springs downward and drive in pad retaining pins to stop.
  6. To finish installation, reverse remaining removal procedure. On RS6, notch on damper bracket must face out. Damper bracket mounting points should make full contact with contour of bracket. Use thread locking fluid on damper bracket mounting bolts. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-139121-S24478463152002042500000).
  7. After installing brake pads and before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level, and top off as necessary.
  1. Raise and support vehicle. Remove wheels. Remove brake calipers. See «FRONT CALIPER»(ref-139121-S00073127512002042500000) . Slide rotor off hub.
  2. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-139121-S24478463152002042500000) . If hydraulic system was opened, bleed hydraulic brake system. See «BLEEDING PROCEDURES»(ref-139121-S25310721302002042500000) under BLEEDING BRAKE SYSTEM.

Removal

  1. To catch leaking brake fluid, place sufficient lint free cloths in area of plenum chamber, engine and transmission. Install bleeder hose and bleeder bottle to the front left brake caliper bleeder screw and open bleeder screw. Operate brake pedal until sufficient amount of brake fluid has been pumped out for the brake fluid level in the brake fluid reservoir to sink below the clutch master cylinder supply hose (if equipped). Close front left bleeder screw.
  2. Disconnect and clamp clutch master cylinder supply hose (if equipped) and seal with a plug. Disconnect brake fluid level warning indicator sensor harness connector. Remove reservoir retaining bolt. Remove brake fluid reservoir. To do this press down the locking tab on the reservoir and at the same time pull the brake fluid reservoir out of the sealing plugs.
  3. Disconnect brake lines on brake master cylinder and seal brake lines and threaded holes with plugs from repair kit Part No. 1H0 698 311 A. Remove brake master cylinder nuts. (Scheme 17) Carefully remove brake master cylinder from brake booster unit.

Scheme 16

Scheme 16
Scheme 16

Installation

To install, reverse removal procedure. Always use NEW "O" ring between master cylinder and brake booster. When installing the brake master cylinder and brake booster unit together, make sure that the push rod is correctly located in the brake master cylinder. Apply slight pressure to the brake pedal to move the push rod towards brake master cylinder; this makes it easier to guide brake master cylinder onto the push rod. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . Bleed clutch and brake systems. See BLEEDING BRAKE SYSTEM .

Front-Wheel-Drive Vehicles

Use following illustrations to aid in removing and replacing parking brake cables on Front Wheel Drive (FWD) vehicles. (Scheme 18)- (Scheme 22).

Scheme 17

Scheme 17: Front-Wheel-Drive Vehicles
Scheme 17: Front-Wheel-Drive Vehicles

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

All-Wheel-Drive Vehicles

Use following illustrations to aid in removing and replacing parking brake cables on All Wheel Drive (AWD) vehicles. See - .

Scheme 22

Scheme 22: All-Wheel-Drive Vehicles
Scheme 22: All-Wheel-Drive Vehicles

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26
  1. Disconnect negative battery cable. Remove master cylinder. See «MASTER CYLINDER»(ref-139121-S21452923092002042500000).
  2. Remove trim from under driver's side instrument panel. On vehicles equipped with a manual transmission, remove connecting piece between brake and clutch pedals. Remove brake light switch. See «BRAKELIGHT SWITCH»(ref-139121-S41162370542004030100000). Using Release Tool (T10006) disconnect brake pedal from power booster. (Scheme 28)
  3. Remove T45 Torx bolts from brake booster. Disconnect vacuum hose from brake booster. Remove power booster and master cylinder.

Scheme 27

Scheme 27
Scheme 27

To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . Adjust brake light and clutch vent valve (if equipped) switches. See BRAKELIGHT SWITCH and CRUISE CONTROL VENT VALVE under ADJUSTMENTS. Bleed brake system. See BLEEDING BRAKE SYSTEM .

  1. Raise and support vehicle. Remove wheels. If replacing calipers, disconnect brakeline from caliper, and plug openings. If not replacing calipers, do not disconnect brake line from caliper. Hang brake caliper from body or suspension. Do not allow caliper to hang by brake hose or line.
  2. Disconnect parking brake cables. see scheme 6- see scheme 7.
  3. On all calipers, remove caliper mounting bolts. Remove caliper assembly from wheel bearing housing. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-139121-S24478463152002042500000). Bleed hydraulic brake system. See «BLEEDING BRAKE SYSTEM»(ref-139121-S24915216092002042500000) under BLEEDING BRAKE SYSTEM.

Removal (C38)

  1. Raise and support vehicle. Remove rear wheels.
  2. Disconnect parking brake cable from caliper.
  3. Remove guide pins, or caliper mounting bolts. see scheme 6
  4. Remove caliper, and wire aside. DO NOT allow caliper to hang by brake hose.
  5. Remove pads and retaining springs from caliper support.

Installation (C38)

  1. Use Special Tool (VW 3272) along with Collar (3272) or equivalent, to seat caliper piston fully into cylinder bore. (Scheme 29)
  2. Seat piston by turning special tool until piston is bottomed out in bore.
  3. Install brake pads, note positioning of pad to caliper (pin on pad must fit into groove on caliper piston).
  4. Position caliper. Install caliper mounting bolts.
  5. With engine off, depress brake pedal several times to allow pads to move into operating position.
  6. Top off master cylinder reservoir as necessary. Adjust parking brake as necessary. See «PARKING BRAKE»(ref-139121-S34083744372002042500000) under ADJUSTMENTS.

Scheme 28

Scheme 28
Scheme 28

Removal (C43)

  1. Raise vehicle. Remove wheels.
  2. Secure brake disc with one wheel bolt.
  3. Remove securing bolts from brake caliper housing, when doing this counter-hold on guide pins.
  4. Remove caliper, and wire aside. DO NOT allow caliper to hang by brake hose.
  5. Remove brake pads and retaining springs.
  6. Clean brake caliper housing and contact surface for brake pad.

Installation (C43)

  1. Use Special Tool (VW 3272) along with Collar (3272/1) or equivalent, to seat caliper piston fully into cylinder bore. (Scheme 29)
  2. Insert pad retaining springs.
  3. Insert brake pads, making sure brake pads are located correctly in anti-rattle springs. see scheme 44
  4. Secure brake caliper housing with new self-locking bolts.
  5. Ensure brake hose is not twisted when installed on caliper housing.
  6. Install wheels. Torque wheel lug bolts to specification. See «TORQUE SPECIFICATIONS»(ref-139121-S24478463152002042500000).
  7. Check brake fluid level and top off if necessary.

Scheme 29

Scheme 29
Scheme 29
  1. Raise and support vehicle. Remove wheels. Remove brake calipers. See «REAR CALIPER»(ref-139121-S36923514802004052600000) . Slide rotor off hub.
  2. To install, reverse removal procedure. Use NEW lock plates (if equipped) and mounting bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-139121-S24478463152002042500000) . Install wheels and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-139121-S24478463152002042500000) . If hydraulic system was opened, bleed hydraulic brake system. See «BLEEDING PROCEDURES»(ref-139121-S25310721302002042500000) under BLEEDING BRAKE SYSTEM.

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