Removing and installing brake caliper piston / protective cap / seal, TTS — AUDI

🧭 Before you start

Fits: platform code FV

• Opens: brake fluid

Don't miss

• 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.
• The bleeder screws must be closed.
• If there is damage to any of the piston bores, the brake caliper must be renewed.
• When removing ensure that the bore of the cylinder is not damaged.If there is damage to any of the piston bores, the brake caliper must be renewed.
• The surfaces of the piston and seal must be cleaned only with methylated spirits and then dried.

📋 Procedure

1. 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.]
2. ⚠ 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.
3. To avoid damaging the paint on the caliper, insert a piece of rubber (or similar) between the piston resetting appliance T10145 and the caliper.
4. Use blocks of wood or similar (b) to keep the other brake caliper pistons in place. Also place a piece of wood (c) against the piston resetting appliance T10145(a) to prevent the brake caliper piston from being damaged when it is forced out.
5. Apply compressed air nozzle to threaded hole for brake hose and press piston out of caliper. [Note: The bleeder screws must be closed.]

6. Carefully pry protective cap (1) out of brake caliper using a screwdriver, taking care not to damage brake piston and piston bore. [Note: If there is damage to any of the piston bores, the brake caliper must be renewed.]
7. Remove seal using removal wedge3409. [Note: When removing ensure that the bore of the cylinder is not damaged.If there is damage to any of the piston bores, the brake caliper must be renewed.] [Note: Install all parts supplied in repair kit.Use only methylated spirits to clean the brake components.If there is damage to any of the piston bores, the brake caliper must be renewed.]
8. The surfaces of the piston and seal must be cleaned only with methylated spirits and then dried.
9. Before installing, lightly lubricate seal with lithium greaseG 052 150 A2.
10. Insert seal in brake caliper.
11. Fit protective cap onto brake caliper piston.
12. Press protective cap into groove on brake piston. [Note: Make sure the protective cap is installed in the correct position in the groove on the brake piston.]
13. Before installing, lightly lubricate piston with lithium greaseG 052 150 A2.
14. Push piston (with protective cap pressed on) into caliper, exerting even pressure and making sure piston is straight. [Note: Take care to keep the brake piston straight when sliding it into the caliper.]
15. Fit piston resetting appliance T10145 and assembly tool T40325 on brake caliper.
16. Repeat procedure on next brake caliper piston.

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