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revolution337
04-19-2013, 06:26 PM
I'm fed up with having to yank my parking brake to the moon in order for it to hold the car, and I don't really trust just leaving the car in gear on a hill. I tried adjusting the cables underneath the car (using the info from this (http://www.audizine.com/forum/showthread.php/483405-Replaced-rear-caliper-now-e-brake-needs-adjustment) thread), but whenever I go to pull the parking brake handle, its feels normal for like 2 or 3 pulls then gets really loose again, and upon inspection, it appears the left rear caliper never comes "undone". It gets stuck in the "parking brake actuated" position. I can "un-actuate" the stuck caliper by tapping on the spring section in the opposite direction though to get it free again. The right rear seems to be alright. Is this a symptom of faulty brake cables? Is my left rear caliper just seizing? Sorry if my explanation is hard to understand. Any help is appreciated.

Seerlah
04-20-2013, 02:40 AM
Sounds like the little spring part is seizing on you. There is a write up in the B6 section somewhere of what people did to fix it. But it is actually a common issue amongst the B6 guys. Not so much the B5 guys, but it happens.

revolution337
04-20-2013, 07:12 AM
Thats what I was thinking. I tried lubricating the spring with some penetrating oil, didn't seem to help much.

walky_talky20
04-20-2013, 07:29 AM
That is because the problem is actually internal to the caliper. This is very common issue on the B5. Lubing the pivot externally and "exercising" the mechanism will help for a while, but to fix it right you have to tear down the caliper and "rebuild". Clean it out and install new seals.

A normal "caliper rebuild" involves pumping out the piston, cleaning up the piston, new seals, and reassemble. But fixing the sticky e-brake lever issue requires going even deeper. Here's what it looks like when you get the piston out:

http://forums.audiworld.com/picture.php?albumid=161168&pictureid=220932

Everything looks great, yeah? Keep going and you find this:

http://forums.audiworld.com/picture.php?albumid=161168&pictureid=220933

And this:
http://forums.audiworld.com/picture.php?albumid=161168&pictureid=220936

Caused by failure of the external seal at the lever pivot location. Here is the seal removed:
http://forums.audiworld.com/picture.php?albumid=161168&pictureid=220941

Pictures pulled from this thread:
http://forums.audiworld.com/showthread.php?t=2770104

But not many shops rebuild calipers anymore. They just sell you a remanufactured caliper.

I always thought a fantastic quick fix for this issue would be a replacement spring that doubled the tension. But that would really be just covering up the problem.

Seerlah
04-20-2013, 07:38 AM
Easier to pick up a used caliper? Or maybe take this time to upgrade the rear? Have the recipe saved in one of my folders.


Upgraded rears with 255x10mm A6 2002 3.0L rotors (StopTech cross-drilled), and A4 B6 3.0L rear caliper carrier (8E0-615-425G)

walky_talky20
04-20-2013, 09:02 AM
Yes, probably better off to replace the calipers, unless you're adventurous and just want to learn how to do it.

I looked into that 255mm upgrade, but I didn't want to do all the work for a measly +10mm and still have a solid rotor. I'm using this recipe:

Upgraded rears with 269x22mm 2002 A8 rotors and 2002 A6 4.2L or 2002 Passat W8 caliper/carrier.

Just picked up the calipers yesterday. Should have everything installed next weekend. I think I'll do a little write-up with some photos.

revolution337
04-20-2013, 09:21 AM
Awesome info as always walky! Thanks

DeltaAlpha9
04-20-2013, 12:19 PM
I was having this same issue a while ago. I used penetrating oil and worked it back and forth and since it started getting warmer out it hasn't been giving me any issues. The fact that the local Audi dealership wants $400 per caliper doesn't help either.

Seerlah
04-20-2013, 07:16 PM
Yes, probably better off to replace the calipers, unless you're adventurous and just want to learn how to do it.

I looked into that 255mm upgrade, but I didn't want to do all the work for a measly +10mm and still have a solid rotor. I'm using this recipe:

Upgraded rears with 269x22mm 2002 A8 rotors and 2002 A6 4.2L or 2002 Passat W8 caliper/carrier.

Just picked up the calipers yesterday. Should have everything installed next weekend. I think I'll do a little write-up with some photos.

Yes, please do [cool]