Hi, I had the same problem with my A6 2000 and I find that I as able to colapse the caliper first after i spun it in the opposite direction retracting it to its full extent. After doing so I was able to retract the caliper spinning it the opposit way,
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Re: audi s4 rear caliper
Are you sure that the caliper piston is the type that rotates to retract, or is it possibly the type that you have to compress with a C-clamp? If you know for a fact that it is supposed to rotate to retract, then it sounds like your caliper will need replacing. If your brake pads get too low, the metal plate that the pad is secured to will begin to heat up from the friction between the rotor and the plate, causing your caliper to heat up and further causing the piston to expand and seize up. Calipers and heat just don't agree. Anyways, if it won't compress, that's what has happened. The good news is that, although you drive an Audi, brake calipers are usually rather inexpensive, so don't be too upset if you end up replacing it. One word of advise that I always stress though: If there is two of anything on a vehicle, I'll never replace one without replacing the other...just a standard I won't budge on. Not to mention, it's nice to have already done the preventative maintenance and trust me...you'll appreciate your rear calipers being balanced too. Hope this helps! Have a great day!
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You are right in attempting to screw the caliper piston back in! But you will need a special tool to assist you though, it locates into the 2 holes in your caliper piston and it will look similar to the one in the picture:
Go to the auto parts store and ask them for the "rear brake caliper tool to retract the piston". This comes as a square and has sides with different spaced tips. Use your 3/8" ratchet and a 6" extention and as you turn slowly, push inward. This will colapse the piston back into the housing (caliper) and allow you to reinstall the caliper to the hub. The tool costs about $10. Let me know if you need anything else.
You must be very careful or this brake job will get very costly, depending on the brake system on this car, one you may have the caliper type that you need to use a tool that turns the caliper piston while it slowly compresses it, then you may have the style caliper with electronic praking brake actuator then you will need a scan tool to do the job, hopefully you did not damage the piston,hope this helps,if theres a small module box on the caliper then you will need scan tool. if it just the caliper with a emergency brake cable going to it then you need the tool that turns the piston by the notches on the face of piston.
Make your own tool using the old pads or 2 pieces of 10mm flat bar.
Drill a hole in one of them(Drilling old pads is difficult - Theyre
extremely hard). Flatbar is easier to drill. Weld a nut over the hole
so that a bolt(should be about 80mm 2-3 inches) screwed into the nut
will pass through the hole. Use as per diagram. Unscrewing the bolt will
pry the caliper open. (Be sure to open the brake fluid reservoir.)
Making this will take you 10 minutes and cost next to nothing.
Dont go forcing the calipers with a screwdriver, wrenches, crowbars or
other manner of strongarm tactics. :-p. It will damage the piston
and/the caliper guide pins
For front brake pads replacement you need only usually wrench set, inclusive 7 mm allen key also. But for rear brake pads replacement you need obligatory a special caliper piston pressing tool, in order to press back rear caliper piston with parking brake automatic adjustment!!! For front brake pads. You must buy the brake pads with wear sensor. For change front brake pads you must raise vehicle, remove wheels, extract the retaining spring of the caliper, and remove the caliper as follow:
1. Do not disconnect the brake hose from the caliper, and do not allow the caliper to hang by the brake hose!
2. Remove top and bottom caps (on back side of the caliper) for access to guide pins, then unbolt and remove them from the brake carrier. Remove the caliper.
3. Now you must thoroughly clean the brake calipers (free of grease).
4. Remove outer brake pad from brake carrier.
5. Pull inner brake pad out of brake caliper piston.
6. Check up the brake fluid level on the reservor, and emptying if neccessary!
7. Push piston back into brake caliper housing.
8. Install inner brake pad (with expanding spring) in brake caliper piston. (Arrow marked on pad - if exists, must point in direction of brake disc rotation when vehicle is moving forward).
9. Install outer brake pad into brake carrier.
10. Bolt brake caliper housing to brake carrier using two guide pins. Tightening torque is 25 Nm.
11. Install both caps.
12. Insert retaining spring into brake caliper housing. Important: Depress the brake pedal firmly several times while the car is stationary so that the brake pads adjust to their normal operating positions!!! Check brake fluid level and top up if neccessary!!!
You will need a 7mm allen wrench or socket the socket is easier with a ratchet to undo the 2 bolts that hold the caliper on.After you take the bolts out take a screw driver and pry up on the caliper to release it off the rotor. your calipers are on top of the rotors. To compress the caliper pistons in take a pair of channel locks that open up alot then with the back brake pad still on squeeze the piston and pad in. That should do it :)
'B6' (2001-2004) A4s dont have seperate rotors on the rear brakes like the pre 2001 A4s do. When changing the rear pads + discs the only special tool you will need is a caliper wind back tool. Let me know if you do also need to replace any ABS components aswell as I might be able to advise.