Sticky Handbrake mechanism - Rear caliper.

[Dezzy]

Originally Posted by Simon Wallwork

Conan

The brakes only get hot if I've used the handbrake.

They don't bind at all otherwise, so it's a problem with the h/b mechanism.

But how to fix it???

After a wet day yesterday playing with the calipers it is the handbrake leaver not returning that makes it stick on. Both were seized to the point i had to knock at them with a small hammer to start them off with a drowning of a homemade penetration liquid. Once they started moving by hand and plenty of oil i got a large screw driver between the caliper and the leaver and prised it away from the caliper. The round bar that goes inside the caliper was badly corroded I scraped this with a small screw driver and filed to finish it off, plenty more oil and one side is now ready to go back on the car with a new seal kit if Audi ring me this morning to tell me they got it in (as promised) I’ll take some photos of the other side to upload.

[Simon Wallwork]

Dezzy
We got the same prob.
I knocked the lever back with a hammer to release the h/b. Did it 20 times with a mate hauling the h/b on in between hammerings!

It'd be great to hear how you fix your calipers. It seems to be a weakness on the D2.

I've just had her MoT'd so ok for a year!

S

[Dezzy]

Need to remove the caliper from the car really as a bench and vice come in handy and working under a wheel arch outside in the rain isn't the best.


Caliper on the bench with the return spring removed, a little care needs to be taken as the spring it under a bit of tension.


Looking at the dirt bild up between the handbrake lever and the caliper body.


I used loads of 3in1 with a bit of white sprits to thin it down and worked the leaver back and forward untill my hands were sore. Then a large screwdriver between the lever and body and with a wiggle, twist and a bit of levering it will come away from the body.


Leaving this. I, like John, couldn't get the lever all the way out. (on either caliper)


Looking down and the dirt / rust build up is thick.

[Conan_the_Librarian]

Top work mat. Thanks for the photos. Added to sticky.

[Dezzy]

Scraped at the muck with a small screwdriver (is all i had) got it back to a reasonable state.


Then filed it smooth (ish)


But was left with some pitting. I used loads of brake cleaner and blue paper roll between these photos.


Put back together with plenty of 3in1 oil working it all the time. You can actually see the rubber seal now.


New inside seal fitted as Audi came good with the kit. Just the dust seal to fit.

The handbrake leaver was moving back on it's own without the spring fitted and before it was cleaned i had to tap it with a hammer to move it.
The seal between the leaver and the body on one caliper is shot and put it down to the amount of build up on the bar. This seal is not in the repair kit and would think that it's only time before i get more trouble.
Maybe if it were kept clean and well lubricated in there the seal would be ok and it would last for years.

Oh i did both side but would suggest keeping one caliper complete for referance as it is not obvious how the spring goes back.

[Simon Wallwork]

Dezzy
Great pics! I think you've explained that job really nicely.

Shame that little seal is not in the repair kit because without it the trouble looks likely to return. Is that seal completely unavailable then?

I suppose if you assembled it with loads of anti-sieze compound it might last for a year or two.

I think in this case, a new caliper makes sense if not too expensive. Wonder what they cost from, say, Euro car spares?

[r8dream]

http://www.brakeparts.co.uk/
or seal kit with small seal £14

[Oli18]

Originally Posted by r8dream

http://www.brakeparts.co.uk/
or seal kit with small seal £14

Nice online shop they've got actually. Dezzy, thanks for sharing 'how-to' mate...really thorough!

Oli

[Night Train]

Thanks for the link, they've got some stuff for my old classic still listed, so most useful.

[billblank]

I feel so guilty for just swearing a lot and throwing on a new caliper for peace of mind. I have an odd rule of thumb that if the new part is under the cost of a tank of petrol then just swap it out. Too many hours spent being skint working on old cars in the rain with no skin on my knuckles in my youth.

Fantastic piccies and write up though. I only put this up as a joke, the pennies the new caliper cost brought out my indolence gene.