Piston for front brake caliper, removing and installing

WARNING: This page does not describe the selected car, but rather 17 other vehicles, including the 2009 Audi S4, 2009 Audi A4, 2008 Audi S4, 2008 Audi RS 4, and 2008 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Assembly paste G 052 150 A2

Fig 1: Identifying Trim Removal Wedge 3409

GW00002640

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Trim removal wedge 3409

Fig 2: Piston Resetting Tool T10145

GW00006810

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Piston resetting tool T10145

Removing

Fig 3: Force Piston Out Of Brake Caliper Housing Using Compressed Air

GW00006869

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Use compressed air to force piston out of brake caliper housing.

NOTE:

Place a piece of wood in the recess to prevent damaging the piston.

Fig 4: Removing/Installing Seal Using Trim Removal Wedge 3409

GW00019763

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove seal.
Use trim removal wedge 3409 for this step.

NOTE:

When removing, make sure that the surface of the cylinder is not damaged.

Installing

Fig 5: Removing/Installing Seal Using Trim Removal Wedge 3409

GW00019763

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert seal.
Use trim removal wedge 3409 for this.

Fig 6: Placing Protective Cap With Outer Sealing Lip On Piston

GW00019764

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place protective cap with outer sealing lip on the piston
The surface of the piston and seal should be cleaned using only methylated spirits and then dried.
Apply a thin coat of lithium grease G 052 150 A2 to piston and seal before inserting.

Fig 7: Inserting The Inner Sealing Lip Into The Grove In The Cylinder Using Wedge 3409

GW00002661

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using trim removal wedge 3409 , insert inner sealing lip into groove of cylinder.

NOTE:

When doing this hold piston in front of brake caliper housing.

Fig 8: Pressing Piston Into Brake Caliper Housing Using Piston Resetting Tool T10145

GW00019765

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press piston into the brake caliper housing using piston resetting tool T10145.

NOTE:

The outer sealing lip of the protective cap will then lock in the groove on piston.