Mechanics

PADS AND ROTORS REPLACMENTS

1999 Audi A6

Brakes problem
1999 Audi A6 6 cyl Four Wheel Drive Automatic

Hi, first of all, let me say this website is awesome!
I just watched the DIY video on replacing brake pads and rotors, will be very informational for a first timer.
I'm going to replace the pads and rotor on my audi, i've done it a few times on my VW, my question is will it be straightforward to do like the video on your site- or maybe you can direct me to vehicle specific site. Thanks for your help!
Avatar
Chin1chin
November 18, 2008.




This is an easy repair just like your VW

Removal & Installation
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.
On all calipers, remove caliper mounting bolts. See Fig. 2 -Fig. 3. Remove caliper assembly from wheel bearing housing.
To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Bleed hydraulic brake system. See BLEEDING BRAKE SYSTEM under BLEEDING BRAKE SYSTEM.
FRONT PADS
NOTE: If re-using brake pads, mark them so that they can be installed in their original positions to prevent uneven braking.

Removal & Installation (FN3)
Raise and support vehicle. Remove front wheels. Secure brake disc with a wheel bolt.
Remove protective caps. See Fig. 2. Using a flatbladed tool, pry off brake pad retaining spring from brake caliper housing and remove.
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.
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.
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.
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.
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.
Install wheels and tighten to specification. See TORQUE SPECIFICATIONS. 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)
Raise and support vehicle. Remove front wheels. Secure brake disc with a wheel bolt.
Using screwdriver, pry off brake pad retaining spring from brake caliper housing and remove. See Fig. 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.
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.
NOTE: Use only methylated spirits to clean the brake caliper housing.

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.
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.
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.
Install wheels and tighten to specification. See TORQUE SPECIFICATIONS.
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 (HP2, Aluminum Caliper)
Raise and support vehicle. Remove wheels. Install one wheel bolt to secure brake disc.
Disconnect connector for brake pad wear indicator. See Fig. 17. Disengage connector from bracket using a screwdriver and simultaneously turn connector 90 degrees. Lift connector up and out and disengage wire.
Fig. 17: Locating Brake Pad Wear Indicator (HP2, Aluminum Caliper)
Courtesy of AUDI OF AMERICA, INC.
Press upper and lower spring tensioner out of locking mechanism using pliers. Slide spring to side. See Fig. 18.
Fig. 18: Removing/Installing Upper & Lower Spring Tensioner (HP2, Aluminum Caliper)
Courtesy of AUDI OF AMERICA, INC.
NOTE: Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

Press piston back into brake caliper housing. To do this, insert floating frame using a screwdriver and press powerfully outward.
Use screwdriver to press outer brake pads off brake caliper. See Fig. 19.
Fig. 19: Pressing Outer Brake Pads Away From Caliper (HP2, Aluminum Caliper)
Courtesy of AUDI OF AMERICA, INC.
Press floating frame in direction of arrow until stop. See Fig. 20. Carefully press brake pads out of piston and remove brake caliper housing.
Fig. 20: Pressing Floating Frame Caliper To Remove Brake Pad (HP2, Aluminum Caliper)
Courtesy of AUDI OF AMERICA, INC.
Installation (HP2, Aluminum Caliper)
Clean brake caliper housing thoroughly before installing new brake pads. Be especially careful to remove any residual adhesive foil, left by outer brake pads.
NOTE: The outer brake pads have an adhesive foil on the pad backing plate. Remove the protective foil before inserting.

Fig. 21: Installing Brake Pads (HP2, Aluminum Caliper)
Courtesy of AUDI OF AMERICA, INC.
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. See Fig. 21.
Press floating frame caliper outward until it contacts stop. See Fig. 22.
Fig. 22: Locating Caliper Stop (HP2, Aluminum Caliper)
Courtesy of AUDI OF AMERICA, INC.
Install upper and lower tension (anti-rattle) springs in correct position. See Fig. 4 and Fig. 18.
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.
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 (Brembo)
Raise and support vehicle. Remove wheels. Install one wheel bolt to secure brake disc.
For RS6, remove damper bracket bolts and remove bracket. On all models, disconnect connector for brake pad wear indicator. See Fig. 23. Disengage connector from bracket using a screwdriver and simultaneously turn connector 90 degrees. Remove lower half of connector out of holder.
Fig. 23: Removing & Installing Brake Pads (Brembo)
Courtesy of AUDI OF AMERICA, INC.
Drive out pad retaining pins (arrows). Remove anti-rattle clips.
CAUTION: Before pushing back piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise, if reservoir has been topped off, fluid will overflow and cause damage to finish.

Press off the brake pads from the brake disc and remove pads from the brake caliper housing.
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.
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.
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.
FRONT ROTOR
Removal & Installation
Raise and support vehicle. Remove wheels. Remove brake calipers. See FRONT CALIPER. Slide rotor off hub.
To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. If hydraulic system was opened, bleed hydraulic brake system. See BLEEDING PROCEDURES under BLEEDING BRAKE SYSTEM.

Dave H
Nov 23, 2008.


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