Removing and installing brake caliper pistons, two-piston brake — AUDI

🧭 Before you start

Fits: Audi A8 D4 (4H, 2010–2017)

• Opens: brake fluid
• Special tools named: T10146/5

Don't miss

• Take care not to damage paint on brake caliper when removing brake caliper pistons and protective caps.When removing ensure that the bore of the cylinder is not damaged.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.
• Before installing, apply a thin coat of lithium grease to piston and protective cap Electronic parts catalogue.

📋 Procedure

1. Remove brake pads .
2. Remove brake caliper and disconnect from hydraulic system .
3. 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.When removing ensure that the bore of the cylinder is not damaged.The brake caliper pistons can only be removed one at a time.]
4. ⚠ 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 1) to hold the second brake caliper piston in place in the brake caliper.
5. Place a piece of wood in the caliper to prevent damage to the piston when it is forced out.

6. Apply compressed air nozzle to threaded hole for brake hose and press piston out of caliper.
7. Lever protective cap off brake caliper using removal wedge3409.
8. Take out seal using removal wedge3409(item 2). [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. Apply thin coat of lithium grease to brake caliper piston and seal Electronic parts catalogue.
11. Using removal wedge3409, insert inner seal into groove of brake caliper.
12. Fit protective cap using assembly tool for protective caps T10146/5(item 1) and piston resetting appliance T10145(item 2).
13. Push protective cap onto brake caliper housing and press it in so that it is seated flush all round (arrow).
14. Before installing, apply a thin coat of lithium grease to piston and protective cap Electronic parts catalogue.
15. Hold piston with standard extension (1) and ratchet attachment and press lightly onto protective cap as shown in illustration.
16. Apply compressed air nozzle (2) to threaded hole for brake hose and blow air into protective cap with no more than 3 bar so that cap springs onto piston.
17. Press piston (2) into brake caliper housing by hand.
18. Repeat the procedure on the other brake caliper piston.
19. Install brake caliper .
20. Install brake pads .

🎬 Related video tutorial

Independent AUTODOC tutorial for the same job, filmed on a different model (A6 C5 Avant) — the technique carries over, the fasteners and figures on this page are the ones for your car.

How to change rear brake caliper on AUDI A6 C5 Avant

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