Removing and installing brake caliper piston (1LU / 1LM / 1LX / 1LN / 1LW) — AUDI

🧭 Before you start

Fits: Audi A6/A7 C7 (4G, 2011–2018)

• Opens: brake fluid

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• Take care not to damage paint on brake caliper when removing brake caliper pistons and protective caps.The brake caliper pistons can only be removed one at a time.
• Install all parts supplied in repair kit.Use only methylated spirits to clean the brake components.The brake caliper must be replaced if a brake caliper piston or piston bore is damaged.
• The surfaces of the piston and seal must be cleaned only with methylated spirits and then dried.

📋 Procedure

1. Remove brake caliper and disconnect from hydraulic system (see the separate procedure).
2. Clamp brake caliper in jaws of vice. Use protective jaw covers. [Note: Take care not to damage paint on brake caliper when removing brake caliper pistons and protective caps. The brake caliper pistons can only be removed one at a time.]
3. ⚠ Risk of injury. Wear safety goggles. When pressing out brake caliper piston, DO NOT reach into brake caliper with your fingers. Place a cloth over bore in brake caliper to catch any brake fluid spatter. Wrap another cloth tightly around nozzle of compressed-air gun applied to brake caliper. Always wear chemical-resistant protective gloves to prevent brake fluid from contacting skin. — Use the piston resetting appliance T10145(item a) to hold the opposite brake caliper piston in place in the brake caliper.
4. To avoid damaging the paint on the caliper, insert a piece of rubber between the piston resetting appliance T10145 and the caliper.
5. Use blocks of wood or similar (b) to keep the other pistons in place. Also place a piece of wood (c) against the piston resetting appliance T10145 to prevent the brake caliper piston from being damaged when it is forced out.

6. Apply compressed air nozzle to threaded hole for brake hose and press piston out of caliper.
7. Carefully drive the protective cap (1) out of the brake caliper using a screwdriver (2) (tap it lightly with a hammer (arrow)), taking care not to damage the paint on the caliper.
8. Remove seal using removal wedge 3409. [Note: Install all parts supplied in repair kit. Use only methylated spirits to clean the brake components. The brake caliper must be replaced if a brake caliper piston or piston bore is damaged.]
9. The surfaces of the piston and seal must be cleaned only with methylated spirits and then dried.
10. Before inserting, apply thin coat of lithium grease to brake caliper piston and seal.
11. Insert seal in brake caliper.
12. ⚠ Risk of damage to brake caliper pistons for ceramic brakesThe ceramic inserts on the brake caliper piston act as heat insulators and must not be separated from the brake caliper piston. If the ceramic insert is damaged, the brake caliper piston must be renewed for safety reasons. — Fit protective cap onto brake caliper piston.
13. Push piston into caliper, exerting even pressure and making sure piston is straight.
14. Press protective cap into groove on brake caliper.
15. Repeat procedure on next brake caliper piston.
16. Install brake caliper (see the separate procedure).

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