Help needed !! EPB - do I need a new calliper ?

[Rob2k68]

Having a nightmare - any way to fix this the piston no longer feels connected - I have VCDS or is it a new calliper job ?

 

[pburv]

Having a nightmare - any way to fix this the piston no longer feels connected - I have VCDS or is it a new calliper job ?

View attachment 107240

Sorry to see that mate..
Has the piston just popped out of the seals?
Do you need something like this to push it back in?...

 

[Simon L]

.........................come on guys help a brother out, Rob does as much for this forum as anyone I can think of

 

[pburv]

.........................come on guys help a brother out, Rob does as much for this forum as anyone I can think of

Trying to do my bit Simon...

 

[Simon L]

Trying to do my bit Simon...

Indeed mate but ye posted same time as me Mr quick on the draw!

 

[pburv]

Indeed mate but ye posted same time as me Mr quick on the draw!

Lol..Whilst I was googling EPB issues too...lol
Still can't help Rob out though..

 

[TimWills28]

That's the tool I used when winding my rear calipers back on the 8p and worked fine...not sure about the 8v, no harm in giving it a gentle try if you've exhausted all other methods ..

 

[Rob2k68]

Sorry to see that mate..
Has the piston just popped out of the seals?
Do you need something like this to push it back in?...

I have the wind back tool mate ;o)

It of a story but basically I put the EPB in lining change mode, disconnected VCDS and keys out (think this is the mistake I made) took the old pads out and used the wind back tool. Wound it in as far as it would go but still the piston wasn't going in fully it needed an extra 6mm.

Thinking that the EPB had somehow reset itself I cycled the lining mode again and the piston popped out and won't go back in.

Worse case I'm thinking it's a new calliper in which case has anyone got a part number pleas and cost (its LHS RHD) as two Audi parts guys have quoted my hugely different prices and Mike the parts guru on here is out this week.

Bit of a pain but quick fix is unbolt the brake line from the calliper put the new one on (should come fully open) then just bleed the brakes and lesson learned for making such a daft mistake.

Thanks in advance guys.

@DJAlix Do you know if there's something I can do in VCDS to help with this ? Now it's registered an error and the EPB light on the button itself is flashing nothing is operating in VCDS so I don't seem to be able to retract the EPB motor - thinking if I can do that then maybe the piston will screw back in ?

 

[pburv]

I have the wind back tool mate ;o)

It of a story but basically I put the EPB in lining change mode, disconnected VCDS and keys out (think this is the mistake I made) took the old pads out and used the wind back tool. Wound it in as far as it would go but still the piston wasn't going in fully it needed an extra 6mm.

Thinking that the EPB had somehow reset itself I cycled the lining mode again and the piston popped out and won't go back in.

Worse case I'm thinking it's a new calliper in which case has anyone got a part number pleas and cost (its LHS RHD) as two Audi parts guys have quoted my hugely different prices and Mike the parts guru on here is out this week.

Bit of a pain but quick fix is unbolt the brake line from the calliper put the new one on (should come fully open) then just bleed the brakes and lesson learned for making such a daft mistake.

Thanks in advance guys.

@DJAlix Do you know if there's something I can do in VCDS to help with this ? Now it's registered an error and the EPB light on the button itself is flashing nothing is operating in VCDS so I don't seem to be able to retract the EPB motor - thinking if I can do that then maybe the piston will screw back in ?

looked everywhere for you mate but didn't come to much I'm afraid....
This is the info on the parts database...I think..
http://www.oemepc.com/audi/part_sin.../615/subcategory/615060/part_id/261393/lang/e
But you probably already know that..lol

 

[TimWills28]

Little idea, you tried turning car ignition on and taking the epb handbrake off/pushing it down to see if it releases?

 

[pburv]

Stating the obvious ...lol
This is on the RossTech site.....
http://wiki.ross-tech.com/wiki/index.php/VW_Golf_VII_(5G/AU)_ABS_Brakes#Basic_Setting

 

[Rob2k68]

looked everywhere for you mate but didn't come to much I'm afraid....
This is the info on the parts database...I think..
http://www.oemepc.com/audi/part_sin.../615/subcategory/615060/part_id/261393/lang/e
But you probably already know that..lol

Thanks Paul ;o)

Can't see the actual piston that reacts against the pad on that image - the piston has came fully out and can wobble up and down and is leaking fluid.

Struggling to figure out how the EPB motor and the hydraulics work together. It's almost as if I need to remove the electric part and then try and wind the piston back in then somehow reset the electric motor ?

 

[pburv]

Thanks Paul ;o)

Can't see the actual piston that reacts against the pad on that image - the piston has came fully out and can wobble up and down and is leaking fluid.

Struggling to figure out how the EPB motor and the hydraulics work together. It's almost as if I need to remove the electric part and then try and wind the piston back in then somehow reset the electric motor ?

This is how on the A4 mk3...Can't find A3 8v...Audi workshop manual..
http://workshop-manuals.com/audi/a4...r_for_electronic_parking_brake_and_handbrake/

 

[pburv]

Here's a pic of the motor...I'm assuming they are similar across the VAG range??

 

[jungle650]

Good effort @pburv , sorry to hear about your woes @Rob2k68. What a pain !

 

[Rob2k68]

Little idea, you tried turning car ignition on and taking the epb handbrake off/pushing it down to see if it releases?

Yes mate - nothing operates there's lots of brake and EPB warning lights on the dash and the handbrake button itself if flashing red. Thanks for the idea though.

Stating the obvious ...lol
This is on the RossTech site.....
http://wiki.ross-tech.com/wiki/index.php/VW_Golf_VII_(5G/AU)_ABS_Brakes#Basic_Setting

As above mate, I can't do anything else in VCDS whilst I have these errors. Might clear them and then try but waiting to hear if Alex has any ideas. Can't imagine I'm the only one this has happened to ;o(

 

[Rob2k68]

Found these pics of a Golf R calliper on Ebay, the EPC and hydraulics react on the same piston and must have some sort of seal/o ring between them .....

 

[pburv]

Here's a better diagram of your typical VAG setup?

 

[Rob2k68]

Here's a better diagram of your typical VAG setup?
View attachment 107276

That's useful mate - describes what I'm thinking that the electric part is exposed to but also seals the hydraulics. Without the pads and discs there the motor has powered out fully and pushed the piston passed the seal. Just not sure how to fix it.

 

[DJAlix]

Only just seen this, sorry Just got in and gonna make a cup of tea, then dig out all the information I can find. I should have all the workshop info on my NAS.

 

[pburv]

That's useful mate - describes what I'm thinking that the electric part is exposed to but also seals the hydraulics. Without the pads and discs there the motor has powered out fully and pushed the piston passed the seal. Just not sure how to fix it.

In one of the many(sorry) pics I have posted there is a diagram of how to remove the motor..In this pic it shows the use of some sort of torx socket being used to rewind the piston...Try this route? and slowly push the piston back in trying not to pinch the seals...There are plenty of calipers on the 'bay' but none that specifically say are for the S3..Are they different to other models? ie piston diameter/stroke....Either Way it looks like a pig of a job to sort out....Getting grief from her indoors now......She wants the pc back...lol.
Good luck Rob. I will catch up with this thread in the morning...

 

[DJAlix]

Check this document out: https://www.dropbox.com/s/ks6nrcmz9a4ntd1/D3E804C3029-Brake_system.pdf?dl=0

 

[Rob2k68]

Only just seen this, sorry Just got in and gonna make a cup of tea, then dig out all the information I can find. I should have all the workshop info on my NAS.

No worries mate no problem at all.

Any info will be very welcome indeed !!!!, two different Audi parts guys also struggling with this.

 

[Rob2k68]

In one of the many(sorry) pics I have posted there is a diagram of how to remove the motor..In this pic it shows the use of some sort of torx socket being used to rewind the piston...Try this route? and slowly push the piston back in trying not to pinch the seals...There are plenty of calipers on the 'bay' but none that specifically say are for the S3..Are they different to other models? ie piston diameter/stroke....Either Way it looks like a pig of a job to sort out....Getting grief from her indoors now......She wants the pc back...lol.
Good luck Rob. I will catch up with this thread in the morning...

Check this document out: https://www.dropbox.com/s/ks6nrcmz9a4ntd1/D3E804C3029-Brake_system.pdf?dl=0

Thanks both ;o)

I'm spent myself now so will have a read through first thing in the morning will use the wife's car for work tomorrow so no overtaking !!

 

[Rob2k68]

So it looks like the motor unbolts and operates a splined shaft in the calliper .....

This is the calliper and what I may need to replace ....

 

[davc]

Sorry to hear about your woes Rob.

I know a guy who runs the parts dept at a VW dealers and could probably help you out with illustrations, p/n's and prices if you're still at a dead end.

He's sorted me out with stuff more times than I care to remember.

Drop me a PM and I'll put you in touch with him if you're struggling.

 

[Simon L]

Hope you get it cracked tomorrow mate

 

[Sean6211]

Rob, it looks like you ran the piston off the threaded end of the splined shaft.

First, remove the entire caliper from the rear hub and work on it on a bench. Disassemble the EPB module from the caliper assembly till you have access to the splined end, as shown in the photos above.

While pushing the piston back into the bore with a suitable tool (improvise here, maybe a screwdriver), use an E11 torx bit or a pair of pliers (cushion the jaws to prevent damaging the splines) to turn the shaft. It should eventually pull the piston back into the bore completely.

Remember to bleed the brakes when you refit the caliper.

 

[Rob2k68]

Sorry to hear about your woes Rob.

I know a guy who runs the parts dept at a VW dealers and could probably help you out with illustrations, p/n's and prices if you're still at a dead end.

He's sorted me out with stuff more times than I care to remember.

Drop me a PM and I'll put you in touch with him if you're struggling.

Thanks Dave, I think 8V0615423E is the caliper that I need. Just sent Coventry Audi an email and will ring them once they open. Yesterday they sent me an image of the EPB motor so hopefully now it is clearer.

Rob, it looks like you ran the piston off the threaded end of the splined shaft.

First, remove the entire caliper from the rear hub and work on it on a bench. Disassemble the EPB module from the caliper assembly till you have access to the splined end, as shown in the photos above.

While pushing the piston back into the bore with a suitable tool (improvise here, maybe a screwdriver), use an E11 torx bit or a pair of pliers (cushion the jaws to prevent damaging the splines) to turn the shaft. It should eventually pull the piston back into the bore completely.

Remember to bleed the brakes when you refit the caliper.

Thanks for this ;o) I think for expediency I'll replace the caliper as I'll be doing this by torch light and need the car on the road asap being self employed - luckily today the wife is on a day off so I'm in the family wagon. Also there's a doubt in my mind why when in friction change mode the piston wouldn't fully wind back. When time allows I'll look to repair the one that comes off and keep as a spare or sell.

 

[pburv]

Thanks Dave, I think 8V0615423E is the caliper that I need. Just sent Coventry Audi an email and will ring them once they open. Yesterday they sent me an image of the EPB motor so hopefully now it is clearer.



Thanks for this ;o) I think for expediency I'll replace the caliper as I'll be doing this by torch light and need the car on the road asap being self employed - luckily today the wife is on a day off so I'm in the family wagon. Also there's a doubt in my mind why when in friction change mode the piston wouldn't fully wind back. When time allows I'll look to repair the one that comes off and keep as a spare or sell.

Morning Rob...Glad you made some sort of progress...
That's the good thing about this forum there's always someone here to help out.....
Will your car be ready for Friday's dyno run?
Good luck buddy..

 

[Rob2k68]

Check this document out: https://www.dropbox.com/s/ks6nrcmz9a4ntd1/D3E804C3029-Brake_system.pdf?dl=0

Looks fairly straight forward to replace the caliper (although I said that about the pads !!!!!!!!), in the pdf on page 106 it describes a diagnostic procedures I'm guessing to recalibrate the parking brake. Would you happen to know the VCDS equivalent of these at all please ?

 

[Rob2k68]

Morning Rob...Glad you made some sort of progress...
That's the good thing about this forum there's always someone here to help out.....
Will your car be ready for Friday's dyno run?
Good luck buddy..

Morning mate, I'm hoping so if I can get the caliper tomorrow morning fit and bleed in the afternoon. Then don't even look at the other side until another day !!!! It's the VAG Tuner Expo at Donnington on Sunday which I'm hoping to get to and need to wash the car at some point.

I'll probably look to repair the original one and do some sort of guide on here should it happen to anyone else.

 

[pburv]

Morning mate, I'm hoping so if I can get the caliper tomorrow morning fit and bleed in the afternoon. Then don't even look at the other side until another day !!!! It's the VAG Tuner Expo at Donnington on Sunday which I'm hoping to get to and need to wash the car at some point.

I'll probably look to repair the original one and do some sort of guide on here should it happen to anyone else.

Nice one mate...Hope you make it to the expo.....
Some pics would be nice...lol

 

[airbus319]

Sorry to hear of your woes Rob,

Maybe worth giving these guys a call to see if they'll sell you a rear caliper it may be cheaper and give you the time to repair yours.

http://www.combellack.co.uk/parts-b...ake-Calipers--amp--Carriers-345mm-Discs/0/12/

hope you get it sorted quickly pal.

 

[DJAlix]

Looks fairly straight forward to replace the caliper (although I said that about the pads !!!!!!!!), in the pdf on page 106 it describes a diagnostic procedures I'm guessing to recalibrate the parking brake. Would you happen to know the VCDS equivalent of these at all please ?

Searching through my data base. Will post up what I find.

 

[DJAlix]

Morning mate, I'm hoping so if I can get the caliper tomorrow morning fit and bleed in the afternoon. Then don't even look at the other side until another day !!!! It's the VAG Tuner Expo at Donnington on Sunday which I'm hoping to get to and need to wash the car at some point.

I'll probably look to repair the original one and do some sort of guide on here should it happen to anyone else.

Do what you need to do in order to get to the Expo... Am gonna be there on the VAG Car Coding stand

 

[DJAlix]

Am not finding any information directly relating to recalibration, which is normally what Basic Settings refers to, however in the case of the EPB I think Basic Settings is used to describe the MQB method for opening and closing the EPB. The only EPB information available for VCDS is the following:

http://wiki.ross-tech.com/wiki/index.php/VW_Golf_VII_(5G/AU)_ABS_Brakes#Basic_Setting

I also found this video which suggests my theory might be correct correct:



I order to double check I just looked at the available "Guided Functions" procedures within Vag Can Professional and can only see the following:



This would lead me to believe that there is no true "calibration" procedure for MQB cars... I have however found the following within my notes but I am unable to connect to my car at the moment in order to see if there is anything like it within 03 - ABS on our cars:

Function Test
Prerequisites:

• Connect a battery charger as per repair manual.
• The Parking Brake must be OFF before Basic Setting are possible.

[Select]
[53 - Parking Brake]
[Basic Settings - 04]
Group 010
[Go!]
Activate the Basic Setting.
[ON/OFF/Next]
The brake pads are now opening and closing 3 times.
Important: Wait 30 seconds after the brakes stop moving before carrying out the next step.
Due to a firmware problem in some modules, failure to wait can result in damage to the control module.
[Done, Go Back]
[Close Controller, Go Back - 06]

 

[Rob2k68]

Do what you need to do in order to get to the Expo... Am gonna be there on the VAG Car Coding stand

Thanks Alex - I'll do what you suggested in later posts.

Will be good to meet you.

 

[Rob2k68]

New calliper ariving tomorrow.

8V0615423E £235.18

That'll teach me !!

 

[DJAlix]

New calliper ariving tomorrow.

8V0615423E £235.18

That'll teach me !!

Not fixable then?