256mm Rear caliper rebuild

[Southy]

Has anybody ever stripped and rebuilt 256mm rear calipers? I've got issues with the handbrake sticking and tried fitting a set of return springs to no avail.

What actually sticks on the calipers itself, is it the internal parts?

I'm pretty mechanical minded and have a week off soon where I can crack on with rebuilding them and can source new pistons and seals easily enough through work.

[Thisday]

Use the search, I posted a link to a couple of guides on it recently

[Thisday]

If you can't find let me know

[Leecunningham]

I found it was actually my brake cable causing it to stick

[Steve Neate]

VAG list 8D0698671 as the part number for the inner fluid seal and outer dust seal. They do not shown any parts for the hand brake part of the caliper.

 

I would find a friendly person at your nearest TPS to give you a top rate of discount, and get new calipers.

 

https://www.thetradepartsspecialists.co.uk/

 

SN

[vRS Joe]

I found refurbishment to be a waste of time with mine. I just got brand new ones off Ebay In the end and I've never had an issue since. Cost me just over £100 for a pair ready painted in green.

Like these http://pages.ebay.com/link/?nav=item.view&alt=web&id=281140544879&globalID=EBAY-GB

[DanHarper]

I found it was actually my brake cable causing it to stick

 

After much cursing of mine and eventually swapping the calipers I found I still had exactly the same problem... need to swap the cable at some point :(

 

£100 off ebay for a pair of green painted ones with the logo ground off from a place near Birmingham though, not bad

[fabdavrav]

I have rebuild the callipers on both front & back on my old fabia...........however it still did stick...............even with getting new seals & dust skirts & getting the burnt on rubber seal of the pistol & wet sanding etc etc., & also you really need to put penetration fluid between the lever spindle & it's dust skirt as that's where it sticks. However it is well known that the internal return springs were badly designed & fail with age.

[coskev]

As above, I went for the same ones as in Joes link

[Southy]

I've managed to price up a full rebuild kit for fronts and rears with new pistons etc for around £80, the internal mechanics of the handbrake need swapping over to the new pistons so when stripped down I will clean everything up before rebuilding them into the new pistons.

[Southy]

Use the search, I posted a link to a couple of guides on it recently

 

i know it's a bit of a while since I posted this thread originally but any chance you could link me up with the rebuild guide? I've had a search and couldn't find anything,

i can get the parts for the calipers cheap enough, but been advised by the sales person the 256 piston swap is rather tricky so would like to read up on it and decide if it's easier to buy new than fiddle about with them. I am rather confident in my mechanical skills/

[hutchysrs50]

They screw out and screw in really...

It's harder putting the piston back in because you need to put the new seal in first, but that's about it.

[Southy]

I've been advised there is a circlip at the bottom which needs removing for the piston internals?

[hutchysrs50]

Yeah that's part of the worm drive. I only replaced seals, not pistons so have no advice for that I suppose.

[Adam_]

Good guide here http://www.audiworld.com/forums/audi-100-a6-c4-platform-discussion-24/rear-caliper-rebuild-guide-2770104/

[Southy]

Good guide here http://www.audiworld.com/forums/audi-100-a6-c4-platform-discussion-24/rear-caliper-rebuild-guide-2770104/

Awesome that's exactly the kinds thing I was after. Doesn't look too bad of a job now I have seen it done.

[alex_e3]

Only bit that gets me is how I'm going to compress the spring down enough. I'm not sure if I have anything deep enough. Hopefully a deep socket will to the job, then just a good old g-clamp!

 

Maybe a valve spring compressor may work too...

 

 

I want mine powdercoated to match everything else in green (tart!), so buying new I'd have to do the same thing!

[Adam_]

I used a deep socket and G clamp to compress the spring. The way he shows in the video would be better as with a G clamp in the way the circlip is difficult to reach.

Also the circlip pliers I bought had needle tips these snapped off first time I used them so I used a grinder to thin the end to a point and then they were fine.

[hutchysrs50]

First time I've actually seen the caliper fully stripped down with the handbrake mechanism out, it's easy to see why they stick on sometimes when they look like that!

I have a full set of brakes I might considering refurbing on a rainy day in the man cave

[alex_e3]

I'm doing this very soon so will take some pictures of the internal parts. I already have the pistons out...  I was waiting on my circlip pliers to arrive!

[Southy]

I've had handbrake issues for a while now but the last day or so I have noticed a front caliper sticking on slightly. I thought with me being off I may aswell tackle fixing the lot of them.

I used 2K Kawasaki Green paint to paint my brakes and it is doing really well, nice hard wearing and brake dust isn't sticking to it much, and I applied it via brush and got a decent finish.

[Thisday]

i know it's a bit of a while since I posted this thread originally but any chance you could link me up with the rebuild guide? I've had a search and couldn't find anything,

i can get the parts for the calipers cheap enough, but been advised by the sales person the 256 piston swap is rather tricky so would like to read up on it and decide if it's easier to buy new than fiddle about with them. I am rather confident in my mechanical skills/

Sorry hadnt seen your post.

There 2 guides in here in different posts,

http://www.briskoda.net/forums/topic/274004-caliper-rebuilding