MoT Failure - Handbrake
 

:( Failed due to handbrake not meeting spec. I did think that it was getting near the stops. The garage are holding the car pending further investigation on monday but i fear that the cables are stretched. The calipers were refurbed in 2015 and then sent back to Big Redd for an "out of warranty" refurb due to a leaking handbrake shaft seal in 2019 so they SHOULD be ok :rolleyes:. Are the cables still available? Does anyone have the part No to hand?
Its a pity this happened right now as I was about to try and steer some minor paint repairs and a detailing through the Financial Scrutiny Committee. (Consist of 1 member:rolleyes:)

Left side is 4D0609721K
Right side is 4D0609722K

Both available from Audi Tradition (purchasing issues for UK buyers, although Dean can assist with that). Right side is 77 Euro and left side on offer for 36 Euro. Cheaper brands available on eBay.

Thanks Sean+++

Just tighten it up. Replacing them is a hell of a job involving a lot more stuff than just the cables (exhaust and propshaft off, things will get broken).

Tightening needs a 4 foot extension and a 13mm socket and can be done without removing anything, although it helps being on a lift. Just a couple of turns on the nut is usually all it takes.

I would check that the handbrake lever on one (or both) of the callipers hasn’t seized. I just went through the same thing at MOT time. Both of my rear callipers have been refurbed, but with little use, the handbrake mech does seize remarkably frequently…..nothing to stop crud getting in. It feels like the cable has stretched, but it may be fine. I had a spare calliper, swapped it out, and handbrake now engages with 3 or 4 clicks..

Zip

That's what i was hoping ( I read the manual on replacement - even tightening is, as you say, a PITA which in the service manual requires propshaft removal! WHO DESIGNED THAT!?) and I havent got a lift! I'll have a face to face meeting with the garage on Monday.
Thanks for the response - Ill certainly make sure they check out the mechanism at the caliper, Zip +++

Assuming the garage has a lift, or at least an MoT pit, then the adjuster nut can be reached with a long extension over the top of the exhaust. Its fiddly but entirely possible without taking anything apart. I'm sure I posted a picture of it somewhere - possibly in the barnfind FE thread.

Thanks MJ, yes i was looking for that in order to educate the local garage guy and to have a sound basis for that that discussion

The adjuster is in here, above the prop where the green arrow is.

I go in from above the centre silencer with a long extension, over the top of the exhaust and propshaft.

http://forum.a8parts.co.uk/attachmen...1&d=1677276628

Thanks MJ+++

MJ had a bit of a write up here as well.

http://62.255.96.108/showpost.php?p=...&postcount=107

I've a question for those in the know.

As most know, my D2 spends most of its life parked in a garage - I have been leaving the gearbox in Park, of course, but with hadnbrake off.

Which is best to prevent future issues?

1. Handbrake off
2. Handbrake on
3. Handbrake on, but only very slightly

Handbrake off definitely. That way when a caliper seizes the car still moves :D

For MJ,
Earlier you said this can be done without removing anything yet in the thread referenced by Strummagnet you drop the exhaust and remove the heatshield. Before I visit the garage tomorrow can you advise if it can be done without the faff of removing stuff? Thanks MJ+++

Yeah it can be done without removing everything. Its fiddly and needs a long extension and a torch but it is possible +++

+++

Ask them first to check handbrake lever shafts on both calipers to make sure that they are moving freely and the springs return them back all the way when releasing handbrake before trying to adjust cable.

Thanks Ainar, yes I did exactly that this morning and took them them the service manual extract and MJ's picture of access. Even told them the size of the socket needed to fit the adjuster.

5 mins ago they just phoned to say a caliper needs replacement. That's after it was removed and freed up in Feb 21 and that after a full refurb by BiggRedd in Dec 2019. So, im pretty cheesed off at the mo and not convinced it needs replacement. Just looking at prices/options etc right now before heading to garage and having a discussion/look see.

The moisture gets in by the handbrake lever shaft in the caliper and start corroding, which introduces extra friction and the spring does not fully return the lever when handbrake is released, this means self adjusting mechanism in caliper is not working properly.

It's a design feature for the Audi's of that era. Was a problem on all I had with quattro, not sure if quattro are more affected as I never had front wheel drive long enough. If you spray some penetrating oil and exercise the lever it usually frees up enough and self adjusts inside caliper so that it passes MOT and is good enough till next year. Small amount of waterproof grease where the shaft enters calliper might help to seal it off and slow the moisture ingress.

Just spoken to garage and, as you suggest, its the lever seized. This happened 2 yrs ago and they just freed it up. This time the easy option (for them!) is to replace it and, tbh, if the seals has let water/grime in again it may be the best thing to do. I'm getting them to price a replacement but will have a go at BiggRed to see what they might say. AFter all, i would expect more than 15k miles and 7 yrs from a fully refurbed caliper. The refurb by them in Dec 19 was an "Out of Warranty" discounted refurb!
Anyone got a pair sitting on the shelf they want to sell?

Tbh 7 years is pretty good for a D2 caliper. I tend to treat them as consumables now.

TRW units are about £200 each but quite hard to acquire these days. Chinesium are about £70 each and are everywhere. I'm actually running Maxgear rears on mine - they're supposedly made in Poland and are about £100 each.

4D0615423E Left, 4D0615424E Right.

Thanks for that MJ, TRW on Autodoc are £115 for left and £156 for right :Confused:

Ill check Maxgear out too +++

Handbrake Cable Clips
 

After much thought about refurbs I went with a pair of new Maxgears. Also renewing the discs whilst Im about it as I'm saving on labour by doing it myself. The nearside caliper was truly gubbed with the handbrake lever not going the full extent of travel. But the small horseshoe shaped clips securing the handbrake cable to the bracket on the caliper have practically disappeared with rust. Anyone know the part number or substitute?

Not familiar with the item in question, but do you mean item #4 in the attached diagram? If so, part number is N90070303 (73p) or N90070306 (£3.36). If this is it, and you can't get the 03 one from the dealer, FlyingSpares.com sell them at 95p and they are in stock:

https://www.flyingspares.com/retaini...n90070303.html

If none of the above, can you upload a photo of the part in question?

Its N90070303:

http://forum.a8parts.co.uk/attachmen...1&d=1678209348

Grateful to you both +++ Mine are just slivers of rust :rolleyes:

and now ordered!

Weird. Just checked ETKA again and the image for 03 was what I posted, and the image for 06 is what MJ posted.

That dark grey clip is to hold a clevis pin in a brake pedal, although not in a D2. Its not part of the handbrake mechanism, so I think it is incorrectly associated with the part number on google.

Worse, it's ETKA that is wrong. I looked up the pedals and that part number is there, but it's also showing under the handbrake mechanism, as shown in the image above in post #24.

Chalk up another win to MJ, as she's more accurate than ETKA. +++

Spot on, Sean. MJ’s knowledge is usually the one to back! :)

It was, im glad to say, the N90070303 i ordered as i recognised the shape and the grey one has the obvious flat pin which wouldn't allow the cable to pass through! Thanks for the link though Sean, as they (Flying Spares) do indeed have the correct clip in stock +++

Good to know that if we need parts for our A8/S8s, we can rely on getting Bentley parts that will do the job. :ROFL:

Finally got all the parts delivered. +++The Maxgear calipers from Autodoc took 2 weeks with them apologising for late processing. :rolleyes: The calipers have an interesting coating. Its not bare metal but its not a heavy paint coat.
Now the temperature has climbed above 5 deg C I'll get on and fit them.