E-brake froze up

[jlandsverk at tds.net]

I agree with Jesper on this one.  Probably not the cables.    

To eliminate the cables from your search, disconnect them from the caliper and see if the e-brake handle moves freely.  This is a 2 person job because you need to verify their movement at the calipers.

My previous '91 90q 20v had problems with the e-brake and to fix it involved dismantling the rear calipers.

There is a cam on the rear brake that actuates the e-brake and that's where the problem is.  The shaft the cam is on gets very corroded and ends up breaking the seal of the rubber gasket where the shaft enters the caliper body.  

To fix this, you need to dismantle the caliper and remove the e-brake mechanism.  There is a very difficult-to-reach circlip at the bottom of the caliper cylinder.  It's easy to get out, but nearly impossible to get in unless have a very long nosed and thin circlip tool.  I did not and it took me several attempts to return it to its position.  I'm not proud to say my final attempt involved compressing the circlip with dental floss.

Back to the shaft - since it's very corroded, you'll need to polish it back up to restore it to a semi-smooth surface.  To reassemble, you'll want to replace that rubber seal the shaft goes through.  A bearing shop or something like that should be able to help.  I didn't replace mine because I was too lazy.

In the end, I coated that entire area of the caliper (after it was reinstalled) with high pressure grease in an effort to keep water from ruining all my hard work.

I live in WI and that fix lasted more than 2 years until I traded the car for my current A6 Avant.

Hope that helps.

Joel L.

'99 A4 1.8tq Avant
'96 A6 Avant
'00 VFR (hates salt)
> 
> From: jesper moreau <jesper5ktqm.audi at gmail.com>
> Date: 2005/01/11 Tue AM 09:54:31 CST
> To: Dennis Unsworth <unzie at ixi.net>,  list submissions <quattro at audifans.com>
> Subject: Re: E-brake froze up
> 
> Ah, the ebrake. Who hasn't experienced problems with those on our
> 15-25 year old cars.
> I have a type 44, I believe we use the same system (just like your old
> '86). The cables would probably be the lesser part of the problem. It
> sounds like your rear calipers are freezing up. They could probably
> use to be cleaned up and rebuilt. I know they have rebuild kits out
> there and or you can buy them seperately. each rear caliper has a main
> piston seal, boot and two carrier guide pin boots.
> 
> They are quite easy to rebuild yourself. If you need help, feel free
> to ask. I have rebuilt so many of them. Mine currently work flawlessly
> on my '86 and I rebuilt them 4 1/2 years ago.
> 
> after that, you may want to look into replacing your E-brake cables. I
> got mine from germanautoparts.com (call them 518-899-7807 and tell
> them jesper sent you) you can pick them up for 19 bucks for the left
> cable, 30 for the right ... $49.00 was the best price I could find for
> brand new german OEM cables (and I researched!!!)
> HTH
> 
> Jesper Moreau
> '88 5KTQ rocket
> '86 5KTQ stocket
> 
> 
> On Tue, 11 Jan 2005 08:07:55 -0700, Dennis Unsworth <unzie at ixi.net> wrote:
> > The e-brake, '90 200TQ has been froze up since the weather turned wintry
> > several weeks ago. I had the same problem on the '86 5kTQ - when the weather
> > turned cold and wet or snowy, the e-brake applied just find, but wouldn't
> > release completely. After driving around a while it would finally let go. On
> > the 200TQ, I don't even set it when it gets cold. The handle feels very
> > stiff in the cold, like something could break if I pulled hard on that
> > handle.
> > 
> > Three below this morning, with a winter storm warning and a low forecast
> > tomorrow night of 18 below. In this weather, it really helps to let the car
> > warm up a bit at idle and it's common for people to leave the car running
> > while doing errands. It's the time of year when the e-brake would normally
> > get quite a bit of use. Dousing the calipers with light oil last winter did
> > not help. The e-brake cables were replaced before I bought it 2-1/2 years
> > ago. Any 'been there-fixed that' out there? Ideas?
> > 
> > Dennis