How to I remove this part of the rear brake caliper?

[Tumbler510]

Got them broken down to thie point (for powder coat), but can't figure out how to get this part out.
Special tools needed?

Thanks for any help!

[airjawed]

What part? the part the handbrake cable goes to? Looks like that should just come apart...but it might be seized from all that heat.

[Tumbler510]

What part? the part the handbrake cable goes to? Looks like that should just come apart...but it might be seized from all that heat.

Yeah that part at the top.
Well I need to get everything removed so the powder coating can happen. Ovens and stuff.

[zillarob]

I remember something you had to do on the inside if you were going to work on the ebrake stuff.
See if there is a nut or something in there.

[Tumbler510]

Took a peek inside, and saw a clamp. I tried getting to it with my C-Clamp pliers, but the cylinder is too small to fit. Also, screwdrivers didn't work very well.
Any ideas?

[airjawed]

I don't think that inner clip is for that outside part...otherwise why would there be that nut/bolt on the outside that you removed?

[MetalMan]

That part will push off. It's pressed onto a spline. If you have a small crow bar type of thing, or a wide chisel you can push it off.

[Tumbler510]

That part will push off. It's pressed onto a spline. If you have a small crow bar type of thing, or a wide chisel you can push it off.

OK, then how do I remove the spline, and the rest of the internals? I need it to be bare metal for the sand blasting and powder coating

[Tumbler510]

Think I found a solution. It IS needed to remove that internal C-clip. But you also need a gear puller.

http://forums.audiworld.com/showthread.php?t=2770104

[Believer]

Apparently I fail at reading. Posted the same thing you just did.. lol

[MetalMan]

Think I found a solution. It IS needed to remove that internal C-clip. But you also need a gear puller.

http://forums.audiworld.com/showthread.php?t=2770104

Yes you're right about how to remove the "spline thing".
I did this with a pair of S4 rear calipers I intended to rebuild, but ended up trashing the bodies (kept the internals).
You gotta get creative with the clip removal. I ordered these pliers to get the clip off:
http://www.amazon.com/gp/product/B00...?ie=UTF8&psc=1
Worked like a charm!

One other thing: I don't think you need to preload the inner assembly before removing the clip. After I removed my fancy gear puller concoction the inner assembly didn't retract at all. See if you can simply remove the clip without a gear puller holding it in place.

That guide is a good starting point, but it's a bit different for B5 S4 rear calipers.

[Tumbler510]

I ordered these pliers to get the clip off:
http://www.amazon.com/gp/product/B00...?ie=UTF8&psc=1
Worked like a charm!

Ordered.

Now I can't figure out how to remove these cylinder sleeves.

[MetalMan]

I don't think those are supposed to come out. They aren't a rebuild item and as far as I have seen are intended to be part of the caliper carrier itself.
If they were at some point a separate piece, I'm guessing they are an interference fit to the caliper carrier body and would be damaged by removing them.

[Tumbler510]

I don't think those are supposed to come out. They aren't a rebuild item and as far as I have seen are intended to be part of the caliper carrier itself.
If they were at some point a separate piece, I'm guessing they are an interference fit to the caliper carrier body and would be damaged by removing them.

That's kind of what I was thinking. They shouldn't be too hard to mask off during powder coating.
Now to wait for my 90* deep reach C-Clamp pliers to get the rest of the rears apart...

[MetalMan]

Amazon Prime? Otherwise cancel your order and I'll send you mine to borrow!

[Tumbler510]

Amazon Prime? Otherwise cancel your order and I'll send you mine to borrow!

Not prime. Thanks for the offer, but I'd like to just buy it and have it for the future.
It's thrown in with a few other goodies, so shipping wasn't bad.

[Tumbler510]

I ordered these pliers to get the clip off:
http://www.amazon.com/gp/product/B00...?ie=UTF8&psc=1
Worked like a charm!

OK, I received the pliers, and removed both c-clips. Now the whole assembly sort of wobbles around, but doesn't come out.
Any advice on getting the rest of this assembly out? The above DIY doesn't address it at all. Just says it comes out after unloading the spring.

[MetalMan]

Yes that DIY as mentioned before isn't quite the same for B5 S4 rear calipers, unfortunately.

The metal plate lever seen in the picture from the first post, is that removed from the splined shaft? I think I used a hammer to gently tap the splined shaft through that metal plate and the inner assembly came out.

[Tumbler510]

Balls! I tried tapping it every which way, and nothing helped.
Not even this way:


I have a suspicion that there is a specialized tool to rotate the spring cover off of the spring, and release the tension in the spring/handle.
I will go to the local VW service shop after work and see what they think.

[MetalMan]

The whole mechanism comes out the opposite direction of the arrow you're showing. If that pic is current, I see the black metal plate at the bottom/underside of that picture still. That needs to come off, and I believe is the only thing holding the mechanism in place.

[julex]

I don't understand why you're taking it all apart to single pieces... calipers are heat resistant, they have to take lots of heat and are built to not melt at brake fluid boiling temp ~300F... that's how hot will the caliper get in the oven... Just mask what you don't want PCed, like the bore, and you're done.

[Tumbler510]

The whole mechanism comes out the opposite direction of the arrow you're showing. If that pic is current, I see the black metal plate at the bottom/underside of that picture still. That needs to come off, and I believe is the only thing holding the mechanism in place.

What black metal piece? The parking brake lever? Do you mean UNSCREW it from the rest of the assembly?
(As in the part prominent in the picture of post #1 of this thread)

I don't understand why you're taking it all apart to single pieces... calipers are heat resistant, they have to take lots of heat and are built to not melt at brake fluid boiling temp ~300F... that's how hot will the caliper get in the oven... Just mask what you don't want PCed, like the bore, and you're done.

Because I've come this far, and want to get it done properly. Also, I want to clean out all the built-up crap that may be present, since the brakes are already torn down to this level.

[julex]

What black metal piece? The parking brake lever?
(As in the part prominent in the picture of post #1 of this thread)



Because I've come this far, and want to get it done properly. Also, I want to clean out all the built-up crap that may be present, since the brakes are already torn down to this level.

While you're in there, make sure to replace whatever seals e-brake shaft to caliper. This is the part that dies on our calipers and causes them to seize due to internal rust.

[MetalMan]

What black metal piece? The parking brake lever? Do you mean UNSCREW it from the rest of the assembly?
(As in the part prominent in the picture of post #1 of this thread)

Yes, the parking brake lever. I knew there was a better name for it
It is a press fit onto the shaft which protrudes through it. The shaft has splines that bite into the parking brake lever.
Have you tried what I mentioned in post #18?

[Tumbler510]

Yes, the parking brake lever. I knew there was a better name for it
It is a press fit onto the shaft which protrudes through it. The shaft has splines that bite into the parking brake lever.
Have you tried what I mentioned in post #18?

Got it. tapped the threads downward, and the orange handle separated from the spline at the yellow line.
Now to figure out how to properly align them again...

[MetalMan]

Yep, that's exactly what I was trying to describe lol.

You have these pictures you can use as a reference, so don't delete them!
Also the other lever that is part of the parking brake mechanism may only allow the main parking brake lever to fit one way. So that may help as a point of reference too.

[Tumbler510]

Getting quotes for powder coating them "Shocker Yellow" Best so far is $300.

[Tumbler510]

Is this assembly necessary to rebuild? Looks like I'd need to bend out some clips to get it apart...

[MetalMan]

IMO, no. If you get a rebuild kit it will have a replacement O-ring for the one shown, as well as the output seal that goes around the shaft under the parking brake bracket (others too).
The parking brake mechanism is immersed in brake fluid at all times so I don't really see what can go wrong with it.

[Tumbler510]

IMO, no. If you get a rebuild kit it will have a replacement O-ring for the one shown, as well as the output seal that goes around the shaft under the parking brake bracket (others too).
The parking brake mechanism is immersed in brake fluid at all times so I don't really see what can go wrong with it.

Thought so. I have all 4 rebuild kits, and there's only one O-ring I can't seem to place for the rears, but I'll take a closer look when reassembly starts. It's amazing how the fronts have 1 dust boot and 1 piston seal, but the rears have about 10 pieces/side.

[landfill]

I got mine gloss red for $150.

[Tumbler510]

I got mine gloss red for $150.

Special order color = gotta pay to play

[Tumbler510]

For anyone following this thread, I found a great step-by-step write up of the entire rebuild, here: http://www.passatworld.com/forums/68...-overhaul.html