B5 RS4 Brake upgrade checklist...

SmoothAssault

SmoothAssault

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Hi Guys, I just picked up my RS4 calipers and carriers from my friendly neighbourhood powder coater; they've come out fantastic! Couldn't be happier and so will finally be fitting everything Friday night/Saturday.

I've not done anything like this before, but I'll be working with a couple of guys who have to ensure everything's done correctly. I'm fairly sure I know what is involved and have been researching for a couple of months but to avoid calling the guys over only to find I'm missing a vital element, just thought I'd run this checklist past you guys...

This is everything I have ready...

  • RS4 Discs
  • EBC redstuff pads
  • RS4 calipers
  • RS4 carriers
  • RS4 dust sheilds
  • HEL RS4 braided brake lines
  • Replacement seals, dust-boots and guide-pin bushes
And still on my shopping list...

  • Brake grease/ copper grease
  • Brake cleaner (apparently for the discs?)
  • Brake fluid (DOT 5.1?)
Open to recommendations on the brake fluid as my thinking behind DOT 5.1 is simply "it's a higher number, it must be better". I know I need to avoid DOT 5 as it's fully synthetic and can't be mixed with whatever is in there at the moment. I want the best but price is obviously a factor that needs to be considered. I'm hoping it's not like liquid gold!?

Along with your standard workshop tools I've also bought...

  • 'Eezibleed' brake bleed kit
  • Caliper piston tool
As I said I'm fairly sure about the whole process but I do have one grey area... When I disconnect the existing brake lines, surely I'm going to have fluid pouring out? So what would you advise I do about this? Let it all drain out and refill the whole lot? Or plug the line some how and just top the fluid up?

If there's anything else I've overlooked please let me know.

Thanks.

If you're interested, my B5 RS4 brake rebuild thread is here...
http://www.audi-sport.net/vb/showthread.php?t=83631

I'll be updating it this evening to show the sand-blasted parts and the powder coating.

:arco:
 
All sound good to me the hardest part will be bleeding the system, the rest is almost like doing a brake disc change.

You do have the bolts to mount them on the calipers and carriers together!
 
I'm hoping the Ezibleed I bought will make bleeding a lot easier, but the guys I'm doing the job with are apparently seasoned experts in the old pedal pumping method if it decides to fail on me.

I have the bolts. Stoaksey threw them in when I picked up the rest of the bits from him. I just hope they fit the B6!! :sadlike:

Any thoughts regarding what brake fluid to go for?

Cheers.
 
Stock will be fine.

You would only realy need to upgrade if you was going racing, never had a sigle issue on my B5 running this set-up so you should be fine.
 
Any DOT 4 fluid from Halfords will be fine for general road use.
I'll be changing to Motul 600 DOT 4 fluid shortly. This is better than 5.1 fluid, as recommended by MRC Tuning, as it has a higher temperature rating.

HTH
 
Okay, I assembled everything last night. Getting the pistons in took absolutely ages, but I got there in the end.

I put the pads in place to check I knew how everything was going to fit together. Looking good so far...

SNC00824.jpg


Woke up at the crack of noon :lazy:... Took my car over to the garage and checked the calipers were working with some compressed air (blocked them with a piece of wood so they didn't pop all the way out).

I undid a brake line and let the fluid drain into a container. Then made a start on the epic ball ache that is removing the old brakes. The carrier bolts were a bitch but with those finally off, removed the caliper and tapped off the disc with a rubber mallet, then removed the old shield.

Cleaned up the hub with a brush and started fitting the new brakes. Approaching 6:00pm by now and decided to just bolt everything on, get the wheel on and finish the job tomorrow.

Here's how they look...

SNC00830.jpg


SNC00834.jpg


Pretty tasty. Lots to do tomorrow though; the same for the drivers side, fit the rear braided lines (came with the set, may as well use them), bleed the clutch, then all four corners in whatever the sequence is.

...and if it's not finished by Monday, I'll be walking to work. :happy:
 
lol... or a long walk Monday.

Everything went pretty well today. I started off with the wrong brake line in the caliper but soon realised the ones with the banjo fitting were for the fronts and swapped it over. That was the only error so far.

The shield does not seem to sit parallel to the disc. Is this normal? the disc is definitely sitting flush on the hub but the shield pulls away from the disc at the top. All is secure but wasn't sure if this was normal and was my only other concern.
 
...You wont be going anywhere monday mate, You'll still be in A&E waiting to be seen after that nasty NUT you gave your Steering wheel.:respekt:.

Looking well matey! Better pics tomorrow though yeah ;)
 
lol, cheers Juss. Definitely better pics tomorrow (providing it is still light when/if I finish).

Think the most likely cause of me being in A&E tomorrow will be a stress induced comma brought on by endless attempts at bleeding the clutch. Really not looking forward to that bit :sadlike:
 
looks like I won't be walking to work tomorrow!!!! :laugh:

Started working at 12:00pm finished at 8:00pm, went out testing everything for half an hour and then tidied up the garage till 11:30pm. Long day. Big job. Very pleased it is finished but too exhausted to appreciate what I've done. Time for bed.

Here's some more photos...

before:

SNC00826.jpg



After:

SNC00838.jpg


SNC00839.jpg


SNC00841.jpg



Massive job for a complete novice to undertake. Very happy with the result but could not with a clear conscience recommend anyone else with as little experience as me try this. It is a very lengthy and involved job and you need an extremely good understanding of the brake system... Not to mention a garage full of tools!

I'm sure when I regain consciousness I'll be quite proud of myself, but right now all I can think about is getting some sleep! :lazy:
 
well done my man somewhat shocked it took so long with all the help you had but then when it comes to brakes it better to be safe than sorry. Nice job.
 
Yea, getting the carrier bolts off is like hitting a brick wall. And we would check and double check everything at each stage. We were very careful, probably over cautious! But given my limited (zero) experience I didn't mind taking my time with it.
 
Last edited:
Nice Work Smooth.They look Massive, bigger the better eh!
So hows the Braking then?? Shaaaaarppp
 
lol, yea, pretty much. I got them 70% for the look and 30% actual braking improvement. Really happy with them. Still bedding the pads so being careful not to hammer them too hard, but it certainly feels a lot better under foot.

Only thing I'm not happy with are the spring clips. Was gonna powder coat them hot pink but decided it would clash with the pads, so sprayed them with silver hamerite last minute. I don't think it looks right. Will change them soon.
 
Sorry to bring up an old thread but I have a quick related question - is that a B5 RS4 or B7 RS4 brake line?
Thanks.
 
SmoothAssault said:
I used braided B5 RS4 lines.
Click to expand...

Hi, I'm new to this forum. I have just got a set of these calipers from e-bay for £50. I plan to have them re-furbed by Big red, unless there are any better re-furbishers out there?

I have a couple of questions :-

1) do I need new shields (splash guards) or will the old ones do?

2) I plan to get HEL RS4 brake lines and want to make sure I get the right ones, so when I order these are they year specific, or is there a part number I need to quote?

Many thanks in anticipation of a reply!
 
Wow, this was a long time ago. I bought the RS4 shields along with the callipers, can't remember if you could get away with leaving the stock B6 ones or not, never crossed my mind.

I believe I got the HEL lines too. They were just listed as B5 RS4 braided lines. But if you need the year then I guess the B5 was 1999-2001. They may also refer to the B5 as the 2.7 twin-turbo or bi-turbo.

I hope you also have the RS4 carriers to match the callipers? You'll need those.

Big Red are good guys, I refurbed my brakes myself but bought all new bushes and seals from them - way cheaper than audi. And FYI, I just recently had to replace my discs - £250... each! Had to go with OEM, couldn't find any alternatives. Red Stuff pads were around £120 too.

Still really pleased with the whole setup, even if the infamous RS4 tax does sting when things need replacing.
 
SmoothAssault said:
Wow, this was a long time ago. I bought the RS4 shields along with the callipers, can't remember if you could get away with leaving the stock B6 ones or not, never crossed my mind.

I believe I got the HEL lines too. They were just listed as B5 RS4 braided lines. But if you need the year then I guess the B5 was 1999-2001. They may also refer to the B5 as the 2.7 twin-turbo or bi-turbo.

I hope you also have the RS4 carriers to match the callipers? You'll need those.

Big Red are good guys, I refurbed my brakes myself but bought all new bushes and seals from them - way cheaper than audi. And FYI, I just recently had to replace my discs - £250... each! Had to go with OEM, couldn't find any alternatives. Red Stuff pads were around £120 too.

Still really pleased with the whole setup, even if the infamous RS4 tax does sting when things need replacing.
Click to expand...

Thanks for getting back to me. Yeah, got the carriers with the calipers, sent the lot off today to Big Redd.

I found Brembo Discs on ebay , which i intend to buy soon FRONT BREMBO BRAKE DISCS AUDI A4 (8D2, B5) 2.7 BI TURBO QUATTRO 98-98 | eBay

Please tell me they are the right ones!
 
Those seem spot on mate. Wish someone had told me I could have got brembos!! I asked a few so-called "specialist" garages and they told me they'd only be able to get OEM. At least I know for next time, thanks.

Looks like you've got everything covered, but if you can find the RS4 shields I'd get them. Just think, by using those discs instead of OEM ones you've saved £390 anyway, can probably pick up a pair of shields and still be getting a bargain.
 
SmoothAssault said:
Those seem spot on mate. Wish someone had told me I could have got brembos!! I asked a few so-called "specialist" garages and they told me they'd only be able to get OEM. At least I know for next time, thanks.

Looks like you've got everything covered, but if you can find the RS4 shields I'd get them. Just think, by using those discs instead of OEM ones you've saved £390 anyway, can probably pick up a pair of shields and still be getting a bargain.
Click to expand...

I'm glad that these discs are OK....£500 for Audi one's, no chance:no: I'll do a test fitting once I have everything back, to make sure the original guards are OK before "splash" out on RS4 one's:think:

Can you confirm there are the correct lines? Audi B5 RS4 Brake Lines by HEL Performance

Cheers again!
 
ASHIHARA said:
That brake discs are for S4 B5,not RS4 B5!,so they are not right ones!
Click to expand...

Why do you think they're not right?

2.7 Bi-turbo quattro, 360mm diameter, 30mm thick, radially vented? I'm pretty sure that's what I'm running. Though was surprised as three places did tell me that OEM was the only option.

here's a listing for the OEM ones I'm running...
Genuine Audi RS4 B5 2.7T front pads and discs | eBay

Seem the same? Though do state till 2001 which is more accurate.
 
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Oh dear, maybe there really is no getting around paying for the £500 OEM discs. Puppy won't be pleased, I know I wasn't!

Must admit, I read 2.7 bi-turbo and thought, "that's an RS4" - absolutely convinced. Had no idea the S4's ran the same.
 
Last edited:
When I got the calipers, I test fitted one to the car over the old discs
IMAG1155.jpg
And I measured every thing up and concluded that the 321mm discs were the way to go. Now I'm not so sure guys!Here is a link to the calipers I bought on e-bay eBay - The UK's Online MarketplaceThey are listed as from a
8D5,B5 [1996-2001] Estate S4 quattro , and he got rid, as he was upgrading to RS4 calipers!!Just to confuse matters more, there are 321 mm Bosch discs on e-bay which list the RS4, amongst others in the fitments table ​
2 x Bosch FRONT Vented Brake Discs Genuine Service Part No. BD882 / 0986478985 | eBaySo I'm well confused now :think:
 
The plot thickens! As far as I can tell, those callipers look the same as mine - RS4. I know mine are definitely RS4 as they came off another member's RS4 who I met at Audi Driver International over at Castle Combe. He was switching to a Porsche Cayenne setup, and I had the whole stock RS4 setup from him.

Here's what B5 S4 brakes look like, (nothing like yours)...
:: a4mods.com :: - The Premiere Audi A4 Modification Guide and Pictures Library

So I'd guess the seller just listed them as S4 by mistake, pretty easy typo I suppose.


My discs are definitely 360mm. I've got a feeling ASHIHARA is correct, and that the confusion on the ebay listings is coming from both the S4 and RS4 having 2.7 bi-turbo engines (fooled me too).

Here's some blurb from RS4's wikipedia page confirming the front disc size...

Brakes were also developed jointly in house by Audi's quattro GmbH, not by Porsche as with its predecessor, the RS2. It has 360 millimetres (14.2 in) diameter by 32 millimetres (1.26 in) thick radially vented and floating cast iron discs at the front, with double-piston floating brake calipers, and 312 millimetres (12.3 in) by 22 millimetres (0.87 in) discs with a single-piston floating caliper at the rear, giving the RS4 braking to match, needing less than 50 metres (160 ft) to come to a full stop from a speed of 110 kilometres per hour (68 mph).
Click to expand...
 
SmoothAssault said:
The plot thickens! As far as I can tell, those callipers look the same as mine - RS4. I know mine are definitely RS4 as they came off another member's RS4 who I met at Audi Driver International over at Castle Combe. He was switching to a Porsche Cayenne setup, and I had the whole stock RS4 setup from him.

Here's what B5 S4 brakes look like, (nothing like yours)...
:: a4mods.com :: - The Premiere Audi A4 Modification Guide and Pictures Library

So I'd guess the seller just listed them as S4 by mistake, pretty easy typo I suppose.


My discs are definitely 360mm. I've got a feeling ASHIHARA is correct, and that the confusion on the ebay listings is coming from both the S4 and RS4 having 2.7 bi-turbo engines (fooled me too).

Here's some blurb from RS4's wikipedia page confirming the front disc size...
Click to expand...

Thanks SA, I'm now sure I need the £500 disc's, but I ain't paying that.:no:

Plan B is S4 calipers, are these Audi A4 S4 2.7 Quattro Brake calipers £100 Cash Back | eBay the one's in the The Premier thread? I presume they go with 321mm discs?

I may ask Big Redd if they will take the RS4's in part exchange for these!:idea:
 
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