Front rotor and pad replacement DIY

[Harpbrar]

I am doing the front rotors and brakes tomorrow and wanted to know if you can reuse the brake sensor if it hasn't tripped yet, and can we push the piston back with a c-clamp or do I need the special tool. Thanks in advance.

[jhelome]

you need the brake tool from pep boys its free to rent...

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[jhelome]

and yes u can re use the sensor

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[AdrianLee]

Does anyone know the torque specs for the Carrier to hub bolts (Front and Rear), torque spec for the two caliper to carrier bolts (front and rear) and the torque spec for the 4 spline bolts on the caliper itself to connect the halves? Any info would be much appreciated.

[gunsmoker]

Yeah, I also want to know the torque specs for the two pairs of carrier bolts because I'll be switching to S4 carriers. The spec for the carrier to caliper bolt was mentioned as 140, which seems a bit much. I can't imagine what the larget carrier to hub bolt will be speced to.

[AdrianLee]

I finally got the dealership to give me the torque specs, so for anyone doing their brakes here are all the torque specs needed. Hope this helps everyone


Fastener Tightening Specifications

Brake Pedal Bracket to Body Nut - 8 nm
Brake Pedal Mounting Pin to Bracket Bolt - 8 nm
Electromechanical Parking Brake Control Module Nut - 3 nm
Electromechanical Parking Brake Motor to Rear Brake Caliper Bolt - 12 nm
Front Brake Caliper to Brake Carrier Bolt - 30 nm
Front Brake Carrier to Wheel Bearing Housing Bolt 1 - 196 nm
Front Brake Line Connection to Brake Caliper - 20 nm
Front Brake Pad Bolt - 5 nm
Front Cover Plate Bolt - 10 nm
Gas Pedal Module to Brake Pedal Bracket Bolt - 8 nm
Rear Brake Caliper to Brake Carrier Bolt 1 - 35 nm
Rear Brake Carrier to Wheel Bearing Housing Bolt - 100 nm + 90 degrees
Rear Brake Hose in Brake Caliper - 19 nm
Rear Brake Hose to Brake Pipe Line - 12 nm
Rear Brake Pad Bolt - 5 nm

• 1 Always replace after removal.

[Tineo]

...I'll be switching to S4 carriers. The spec for the carrier to caliper bolt was mentioned as 140, which seems a bit much. ....

hi gunsmoker, i will upgrade to s4 calipers too.

30 Nm is the torque spec for this bolts

[gunsmoker]

hi gunsmoker, i will upgrade to s4 calipers too.

30 Nm is the torque spec for this bolts

It looks like it's 196 Nm. 30 Nm is the carrier-to-caliper bolts torque. I also ordered replacement bolts for the carrier-to-hub-housing bolt as AdrianLee says.
It has a locking washer so it makes sense to replace it.

[Metorn]

How do you remove calipers? OP says remove 2 bolts, which look like 21mm carrier bolts.
Will it release the caliper or you need to undo caliper slider pins/bolts as in older models?

[Limey]

Which bolts do I need for the S5 carrier to hub? These ones?
Self Locking Bolt (M12x1.5x62)
Self Locking Bolt (M12x1.5x38)

[gunsmoker]

Which bolts do I need for the S5 carrier to hub? These ones?
Self Locking Bolt (M12x1.5x62)
Self Locking Bolt (M12x1.5x38)

^^^ These two are for the rear carrier.
The 2 bolts for the front carrier are of the same type:
http://www.ecstuning.com/Audi-B8_A4-..._All/ES472036/

[Metorn]

How do you remove calipers? OP says remove 2 bolts, which look like 21mm carrier bolts.
Will it release the caliper or you need to undo caliper slider pins/bolts as in older models?

Answering my own question :) 21mm are enough to remove caliper with the bracket. However it is possible to take 2x13mm bolts first to remove the caliper/pads only. It makes much easier to remove the remaining 21mm-s - as it provides a clear access.

[bsully1850]

Hi, does anyone know where the brake sensor is suppose to be installed? When I took my caliper off the sensor just popped off the bake somewhere.

[ricktsd]

i've gotten the calipers off, and removed the T30 torx, but cant get the rotor off for the life of me. any suggestions? ive been banging at it with a hammer for an hour with no success. it's not budging.

[ricktsd]

Hi, does anyone know where the brake sensor is suppose to be installed? When I took my caliper off the sensor just popped off the bake somewhere.

it slides into a groove on the inner brake pad.

[bsully1850]

i've gotten the calipers off, and removed the T30 torx, but cant get the rotor off for the life of me. any suggestions? ive been banging at it with a hammer for an hour with no success. it's not budging.

I had one rotor that would not come off, I sprayed some WD-40 around the center, let it sit for about 10 mins and started hitting it again. After a few more blows it came right off.

[ricktsd]

I had one rotor that would not come off, I sprayed some WD-40 around the center, let it sit for about 10 mins and started hitting it again. After a few more blows it came right off.

yea, i eventually did the same thing. too bad the rotors are too worn for resurfacing. now i need to buy some rotors.

[Tm030512]

Subscribed...planning on doing brakes

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[cuda2000]

I'm in the middle of replacing pads and rotors. Found this diagram, doesn't really help me at the moment but might help someone.
Right now I can't get the rotor off, I hit the heck out of it with rubber mallet, but gave up. I put some PB Blaster penetrant on it and left it over night, hopefully it will come off now, otherwise its 5 pound hammer time.
I will make a video when I do the left side.
Diagram:
http://www.justanswer.com/audi/65rqk...n-replace.html

[A4BGP]

No need to hammer the crap out of everything.

Use a nut and a bolt. Put the nut on the inside of the caliper hanger bracket mounting points and feed the bolt from the other side. Tighten the bolt until it makes contact with the disc while holding the nut with a wrench. Snug the bolt and watch the disc pop off. If it's really stuck on there, rotate the disc 180deg and repeat.

[cuda2000]

I finished the job today on my 2010 Audi A4 Quattro, and made a video of it.
http://youtu.be/i00ZIJSOA8w

Hardest part for me was the rotor on the passenger side was really stuck on, but PB Blaster did its job and I didn't have to hit it too hard. The driver's side was not stuck on.
Other than that, the outboard pads were GLUED to the caliper, very difficult to pry loose. I have no idea why there were glued on, this is from the factory, I bought the car new and just replaced the pads and rotors at 37,000 miles.

I used $34 Duralast Rotors from Autozone part #45600 and Ceramic Akebono pads EUR1322 with the sensor included for $84 from Advance Auto Parts.
TOTAL cost $179 vs $650 the dealer wanted! I saw no difference in the Chinese rotors vs the factory ones (see video). First test drive had no issues. I will update if I come across any issues.

[sawy3r]

Nice work cuda2000!

I also just completed this job today, and found the silicon / glue on the outer pad too... Was quite a challenge to pry loose, plus a pain to clean up the face (chisel, brake cleaner, wipe, sandpaper... Repeat x1,000).
I went for Ferodo DS Performance pads (FDS4044), and DBA T2 slotted rotors (DBA 2822S). Not a whole lot of difference yet, but I've only put approximately 15km on them so far. That being said, I think they do bite a little better...

I lost the clip on the pad wear sensor, and a new sensor did not come with the Ferodos. I purchased the replacement sensor (8K0615121) from Audi for $66 AUD. This can be had from ECS Tuning for $39.38 USD for the genuine article, down to $6.21 for the cheapest aftermarket part. I couldn't wait for the shipping time (nor be bothered to pull the wheel off again just replace the sensor), so took the local option.

All in, took me about 8 hours... Far too long, but next time it will be a lot faster. Now to do the rears..

[sawy3r]

I'm in the middle of replacing pads and rotors. Found this diagram, doesn't really help me at the moment but might help someone.
Right now I can't get the rotor off, I hit the heck out of it with rubber mallet, but gave up. I put some PB Blaster penetrant on it and left it over night, hopefully it will come off now, otherwise its 5 pound hammer time.
I will make a video when I do the left side.
Diagram:
http://www.justanswer.com/audi/65rqk...n-replace.html

My left I had to give a decent few whacks... I started with a mallet then noticed OP pics of the metal hammer, gave it a few quick cracks with a mini-sledge and it jumped right off.

[kt883]

I know were talking about fronts but with rear, if we use vcds will we not need a piston retractor for that?

I have a cheap princess auto retractor but would I be able to use that for the fronts?

[booost]

I know were talking about fronts but with rear, if we use vcds will we not need a piston retractor for that?

I have a cheap princess auto retractor but would I be able to use that for the fronts?

Yes you can use just a retractor on the fronts. On the rears, VCDS didn't open the caliper enough for me to get the new pads on so I used the retractor to open them up a little more and did not have issues. I highly suggest using VCDS on the rears, there are reports of people damaging the calipers/motor doing the swap without it.

[drunkandslurred]

I need help, I replaced the front brakes a few years back with no problems. This time around the calipers will not come off the rotors. I removed the 2 21mm bolts and the calipers move up and down freely from the rotors but they will not actually come off the rotors. Any suggestions?

[drunkandslurred]

Nevermind got it. Inserted a screwdriver from the back in the gap and compressed it in.

[sawy3r]

Nevermind got it. Inserted a screwdriver from the back in the gap and compressed it in.

Haha just saw your first post and was about to reply saying to use a crow bar, or something, to separate the pads / compress the piston to get the pads to clear the lips on the rotor.

Took me a while to work it out when I did mine! Glad you worked it out :)

[Acme]

Hello guys.

I'm about to order rotors and pads for my 2013 sedan... Are these the same for all B8 and B8.5?? 320mm rotors and same brakes for all years between 2009 and 2016? Looks like it but someone hinted that it's not the case, so I'm not 100% sure......

Thanks!

[BeerBrent]

Did my front and rear rotors and pads this past weekend. First time on the Audi. Very easy. Thanks for all the info in this thread.
This guy's video was helpful also.
https://www.youtube.com/watch?v=QmKpIJY7RbE