Brake disc (Audi A6 C5)

Table of contents: Removal ↓ Installation ↓

Removal

Use paint to mark the position of the wheel relative to the hub. This is necessary to reinstall the wheel in its original position, which maintains its balance.

With the vehicle standing on its wheels, loosen the wheel mounting bolts.

Raise the relevant part of the car and secure it on stands, unscrew the bolts and remove the wheel.

Unscrew the two bolts shown by the arrows in Figure 11.15 and remove the caliper assembly from the brake disc. The figure shows the front caliper. To remove the rear caliper, unscrew the two Allen-head bolts.

Unscrew the two bolts shown by the arrows in Figure 11.15 and remove the caliper assembly from the…

Remove the brake hose from the bracket.

Raise the caliper and use soft wire to tie it to the front strut, making sure the caliper does not hang on the brake hose, or become stretched or twisted.

Caution: Do not unscrew the brake hose, otherwise you will have to bleed the air from the hydraulic brake system after assembly.

If the caliper needs to be removed, follow these steps.

On the front wheel caliper, clean the area around the junction of the brake hose and brake pipe and unscrew the brake pipe from the brake hose coupling. Close the holes in the brake hose and pipe with suitable plugs.

On the rear wheel caliper, clean the area around the junction of the brake hose and the brake pipe and unscrew the brake pipe at the brake hose connection and, if necessary, unscrew the brake hose from the caliper. Close the holes in the brake hose and pipe with suitable plugs.

Caution. When opening the hydraulic brake, brake fluid leaks out. To reduce brake fluid loss, remove the cap from the brake system refill tank, cover the tank neck with polyethylene and screw the cap back on. This is necessary to ensure that the cap seals the refill tank tightly.

Remove the brake disc.

Installation

Note: If it is necessary to replace the brake disc, the second brake disc must also be replaced to ensure uniform braking. When replacing the brake discs, the brake pads must also be replaced.

Check and, if necessary, clean the mating surfaces of the brake disc and hub. When installing a new brake disc, remove the protective coating from its surface.

Install the brake disc onto the wheel hub.

Install the caliper with brake pads. Do not twist the brake hose. Check that when the front wheel is fully turned, the brake hose does not contact the front suspension elements and the body.

Secure the brake hose to the bracket.

Secure the caliper with bolts and tighten the front caliper mounting bolts FN-3 to 120 Nm and the caliper HP-2 to 190 Nm. If bolts with a ribbed head base are reinstalled, clean the ribbed surface using a wire brush.

Secure the rear caliper with the bolts, tightening them to a torque of 95 Nm. If re-installing bolts with a ribbed head base, use a wire brush to clean the ribbed surface.

If the brake hose was disconnected, screw it back into place.

Remove the polyethylene from the filler neck of the replenishment tank and bleed the corresponding brake circuit.

Connect the parking brake cable to the rear brake caliper.

Apply a thin layer of grease to the flange that centers the wheel disc. Install the wheel, aligning the previously applied marks, and secure it with bolts. Lower the car to the ground and tighten the wheel mounting bolts to a torque of 120 Nm.