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

Rob2k68 Oct 18, 2016

  1. Rob2k68

    Rob2k68 Well-Known Member VCDS Map User

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

    IMG_1261.JPG
     
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  3. pburv

    pburv Registered User

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    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?...
    [​IMG]
     
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  4. Simon L

    Simon L Well-Known Member Gold Supporter

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

    pburv Registered User

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    Trying to do my bit Simon...:whistle2:
     
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  6. Simon L

    Simon L Well-Known Member Gold Supporter

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

    pburv Registered User

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    Lol..Whilst I was googling EPB issues too...lol
    Still can't help Rob out though..:concern:
     
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  8. TimWills28

    TimWills28 Well-Known Member VCDS Map User

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    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 ..
     
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  9. Rob2k68

    Rob2k68 Well-Known Member VCDS Map User

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    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 ?
     
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  10. pburv

    pburv Registered User

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    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
     
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  11. TimWills28

    TimWills28 Well-Known Member VCDS Map User

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

    pburv Registered User

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  14. Rob2k68

    Rob2k68 Well-Known Member VCDS Map User

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    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 ?
     
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  15. pburv

    pburv Registered User

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    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/
     
  16. pburv

    pburv Registered User

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    Here's a pic of the motor...I'm assuming they are similar across the VAG range??
    [​IMG]
     
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  17. jungle650

    jungle650 Registered User

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

    Rob2k68 Well-Known Member VCDS Map User

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    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.

    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(
     
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  19. Rob2k68

    Rob2k68 Well-Known Member VCDS Map User

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    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 .....

    IMG_1263.PNG
    IMG_1264.PNG
     
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  20. pburv

    pburv Registered User

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    Here's a better diagram of your typical VAG setup?
    upload_2016-10-18_19-56-36.jpeg
     
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  21. Rob2k68

    Rob2k68 Well-Known Member VCDS Map User

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    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.
     
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  22. DJAlix

    DJAlix VAG Car Coding™ Limited Site Sponsor Gold Supporter VCDS Map User VAG Can Professional ODIS (Offboard Diagnostic System)

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    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.
     
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  23. pburv

    pburv Registered User

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    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...:friends:
     
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  24. DJAlix

    DJAlix VAG Car Coding™ Limited Site Sponsor Gold Supporter VCDS Map User VAG Can Professional ODIS (Offboard Diagnostic System)

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  25. Rob2k68

    Rob2k68 Well-Known Member VCDS Map User

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    No worries mate no problem at all.

    Any info will be very welcome indeed !!!!, two different Audi parts guys also struggling with this.
     
  26. Rob2k68

    Rob2k68 Well-Known Member VCDS Map User

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    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 !!
     
  27. Rob2k68

    Rob2k68 Well-Known Member VCDS Map User

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    So it looks like the motor unbolts and operates a splined shaft in the calliper .....
    IMG_1265.PNG

    This is the calliper and what I may need to replace ....
    IMG_1266.PNG
    IMG_1267.PNG
     
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  28. davc

    davc Registered User

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    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.
     
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  29. Simon L

    Simon L Well-Known Member Gold Supporter

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    Hope you get it cracked tomorrow mate :)
     
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  30. Sean6211

    Sean6211 Registered User

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    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.
     
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  31. Rob2k68

    Rob2k68 Well-Known Member VCDS Map User

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    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.
     
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  32. pburv

    pburv Registered User

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    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..:friends:
     
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  34. Rob2k68

    Rob2k68 Well-Known Member VCDS Map User

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    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 ?
     
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  35. Rob2k68

    Rob2k68 Well-Known Member VCDS Map User

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    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.
     
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  36. pburv

    pburv Registered User

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    Nice one mate...Hope you make it to the expo.....
    Some pics would be nice...lol:whistle2:
    [​IMG]
     
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  37. airbus319

    airbus319 Well-Known Member VCDS Map User

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  38. DJAlix

    DJAlix VAG Car Coding™ Limited Site Sponsor Gold Supporter VCDS Map User VAG Can Professional ODIS (Offboard Diagnostic System)

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

    DJAlix VAG Car Coding™ Limited Site Sponsor Gold Supporter VCDS Map User VAG Can Professional ODIS (Offboard Diagnostic System)

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

    DJAlix VAG Car Coding™ Limited Site Sponsor Gold Supporter VCDS Map User VAG Can Professional ODIS (Offboard Diagnostic System)

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    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:

    Screen Shot 2016-10-19 at 09.26.39.png Screen Shot 2016-10-19 at 09.26.45.png

    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]
     
    Last edited: Oct 19, 2016
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  41. Rob2k68

    Rob2k68 Well-Known Member VCDS Map User

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

    Will be good to meet you.
     
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  42. Rob2k68

    Rob2k68 Well-Known Member VCDS Map User

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    New calliper ariving tomorrow.

    8V0615423E £235.18

    That'll teach me !!
     
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  43. DJAlix

    DJAlix VAG Car Coding™ Limited Site Sponsor Gold Supporter VCDS Map User VAG Can Professional ODIS (Offboard Diagnostic System)

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    Not fixable then?
     
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