New discs all round from J H Motorsport but have questions..

[justin1230smith]

Hello fellow 6'ers....

I, like everyone else, needed new discs and pads all round but decided this time to move away from OEM rotors and pads and try out JH Motorsports offerings with a seperate bell and rotor assembly. (About £1400 shipped after import duty and VAT before you ask complete with Hawk ceramic pads)

I managed to get the old discs all off last night (they were shagg*d to put it mildly) and have thrown them in the bin !

Before I put everything back together though I thought I would order some replacement parts but have hit a bit of a wall so thought I would ask the group for your advice

First off, with respect to the front calipers...

I was going to replace the long bolts that hold the caliper onto the mounting but neither Audi (or myself on EKTA) could see that they are available without buying a whole caliper !!!

Then I wanted a new set of shims as the dealer must have trapped 3 of them last time behind the stainless slide and they are bent, rusty and dead beyond salvage - Audi say they only come with their pad set but these look more that a set of pads old, they look like they have never been changed - Any ideas here ??

I was then thinking of replacing the stainless slides also but they have a number on EKTA but no part number ?

On the back calipers...

I wanted to replace all four bolts that you have to take off. In fact EKTA says they should not be re-used but Audi can only find a part number for 2 of the bolts !?

Also on the back I was going to change the stainless holders for new ones but again, no part number.

If it's this hard for a customer to get parts when I have all the time in the world then no wonder main dealers are tempted to just whack stuff in when they are against the clock ?

Final question then...

I have all fours wheels going away for re-furbs and colour change to anthracite.

Do the internal pressure sensors have to be in the correct wheel when they go back on ?

Thanks in advance,

Justin - Essex

- -

Full images are here http://www.rs200.org/rs6/rs6.htm

[Shoppinit]

That's a lot of question. By the time I got to the bottom of your post, I forget the top of it.

The last question: No

[justin1230smith]

Shoppinit - LOL - Thanks for that - So at least somethings easy ! - Bung the wheels on and it detects the closest sensor - Nice !

[Daveperc]

Give Grizz (Unit 20) or Doug (MRC) a call - I suspect a conversation will be a lot faster than all that typing!!

Dave

[justin1230smith]

Daveperc - I know, you're probably right but I guess they must get pi**ed off with people like me ringing with a list of questions !!

That said, mine does need a service (300 miles to go) so will be going to one of the two from Essex as soon as I can get it in the diary.

I have answered some of my own questions now so will post here for anyone else doing this type of work.

First off, the pins in the front were stuck very hard and got well dented as I drifted them out and that was with me being really carefull and using penetrating oil.

To get round that I bought 2 fitting kits - 3DO 698 269 - It appears the stainless sliders are no longer available.

Then I found the bolts needed for the rear calipers - WHT 003 250 and N 907 403 02.

What are no longer available though are the caliper bolts to hold the front caliper on ! - Part number: N 100 650 02 (M12 x 1,50 x 70 Grade 10.9) - Also no longer available are the shims that sit behind teh front pads nor the springy metal bits from the back calipers.

S0, 75% sucess so far

[Shoppinit]

Cool. Thanks for posting that part number What's in the kit?

[Shoppinit]

Never mind

How much was the kit?

[grizz]

The calliper mounts don't have to be taken off on the rear , the disc will slide out ,the new rear pads should come with new ss holders & calliper bolts .
New oe front pads come with the little pads .

[justin1230smith]

I'll grab the invoice when in the garage tomorrow and let you know.

[justin1230smith]

Grizz- Thanks for that - Problem is I have moved away from the OE ones and gone for Hawk ceramics so nothing in the box but the pads

I might have to "re-cycle" the shims - I have emailed Brembo to buy some front caliper bolts - Rear bolts all sorted now with the latest finds.

[justin1230smith]

I thought I would finish off the thread I started, if nothing else it will make you laugh ! (or cry as you feel my pain)

After buying all the bits I needed (or so I thought)..

A3DO 698 269 Service Kit - 2 x £16.58
AWHT 003 250 Bolts 4 x .82p
AN 907 403 02 4 x .78p

I went to put the new pads in and found that without some serious hammer work they would not fit in, if they did go in then they were so tight they would have stuck on the discs the first time I hit the brakes.

So, I took the caliper off to have a better look.

What I found was that corrosion had got under the stainless steel sliders so that they were bent upwards and were thus restricting the pad movement, it looked like a chemical reaction between the two different metals.

Simple I thought - lets take them off and clean them underneath - oh no - not so easy, they are held in by 3 x M5 screws that were corroded in so, I had to send them off to be spark eroded out ! - £120 !!!

Then, once I had the caliper back I thought I better replace the bleed nipples, again, what a pain, 3 came out (just) the other was stuck in so had to go away to be teased out and even then it made a mess of the thread it left behind.

At this point I thought, I better check the actual pistons. Low and behold, when you applied pressure some came out OK but none were great, they were all sticking a bit so... you guessed it, I took them out also !

I then looked up the price with Audi for a new set but they were too expensive.

You could see on the dust seals that they were Brembo part numbers 20.4872.40 and 20.4872.42

I shopped around and, with the UK Brembo agent never returning my calls (the calipers are in fact Brembo part numbers 20.7675.02) - I had to order them from abroad with a new set of pressure seals also. (£80 incl shipping) - The pistons are nothing more than a standard 28mm and a 32mm - GPR Motorsport in the UK used to list them for £8 each but are no longer agents

While I waited for the parts to arrive I paint stripped the caliper and re-painted it and, after a new pair of stickers were applied, got some high temp lacquer on the top of it all.

I also took the opportunity to send my wheels off to be chemically stripped and repainted ready for the re-build (4 x £55), it was then that I found one was badly buckled, luckily the original owner had bought a spare so that had to go off to be done also (another £55). 4 new tyres seemed appropraite while I was at it (Vredestein Ultrac Sessantas @ £615 for all 4 from click-on-tyres limited)

So eventually (6 weeks later) I had two rebuilt calipers, all back together, ready to go on the car.

That's not the end of it - I managed to cross thread BOTH pipes going back into the caliper as the 11mm nuts were so corroded (and it was dark and cold out).

I salvaged one pipe but had to buy a passenger side one for £31 (8EO 611 707H).

So, the car was ready to go and then I realised the tax had run out as had the MOT - More money !!!

However, I'm there now, she is all back together and the brakes feel (and look) great.

I don't want to have to do that again in a hurry (nor can I afford to) but my pain might make yours easier should you have to undertake the same job.

Just need some sun now ! - Justin

Rather than make a mess of the thread i've put the rest of the pictures up here again http://www.rs200.org/rs6/rs6.htm

[grizz]

Nice work , The problem with the calipers is a common one ..

[leet]

i had the same problem with my maserati calipers too. Lucily i managed to get the stainless plates off though and filed the corrosion back down

[MalcolmSu]

great set of pics Justin - those original disks were well neglected!