Brembo Front Caliper Repair (Audi A8 D2)

Note: Before screwing in the fittings, apply a thin layer of G 052 150 A2 grease to the threads.

The parts of the caliper bracket housing are connected by bolts with an internal shaped recess and cannot be disassembled. If the protective covers of the guide pins are damaged, they must be replaced with new ones.



Clean the support (Fig. 15–26) from dust and dirt, using respiratory protection.

On one side of the caliper, install a special device for pressing the piston, which will hold the pistons in place, located opposite each other, and on the other side, install a clamp that fixes the piston in the cylinder. Between the clamp and the remaining piston, install a wooden block.

Remove the piston from the caliper by applying low pressure air to the brake cylinder through the brake hose connection hole.







Remove the wooden block and carefully remove the piston. Carefully, so as not to damage the cylinder walls, remove the outer seal from the groove of the caliper cylinder, using a mounting wedge or a flat-head screwdriver blade as a lever (Fig. 15-27).





Similarly, remove the inner seal from the caliper cylinder groove (Fig. 15–28).

Check the condition of the cylinder and piston. If there are scratches, marks, wear or pitting, the piston and cylinder must be replaced. Regardless of the condition, replace all rubber seals.

Wash all parts in methylated spirits or clean brake fluid and wipe them dry.

Apply a thin layer of G 052 150 A2 grease to the sealing ring and piston (see Fig. 15–28).







Install the inner and outer seal rings onto the piston (Fig. 15–29).

Use your fingers to press the piston into the caliper cylinder.

Using a piston presser and special tool 3350/2, press the outer seal 44mm into the caliper body.

Replace the remaining pistons in the caliper in the same manner.