[s-cars] Need Help w G-60 Brake Pad Change

[Wayne Dohnal]

>Pulled the wheels but had difficulty reconciling the Bentley diagrams with
>what I saw on the car.

I did mine last week and I feel your pain.  After much mental agony and
searching of list archives (which have very little info) I concluded that
the front brakes described in the Bentley were only on European S4s, and are
very different from our brakes.  For instance, the Bentley shows 4 pads per
wheel while we have 2.  Another problem is that the Bentley says to torque
the carrier bolts to almost 200 ft-lb, which is way-way too much for our
setup (I also replaced the rotors so had to remove the carriers).  The front
brakes in the Bentley for the Audi 100 are also different than ours.  The
ONLY useful info in the Bentley is the procedure for removing and replacing
the pad wear sensor connector on the metal bracket bolted to the caliper.

I had one seized guide pin on each of my calipers.  From the verbiage in the
Bentley and other sources my conclusion is that Audi's position on the guide
pins and their rubber booties is that if anything is less than perfect
you're supposed to replace the caliper.  I was bad and I cleaned up and
regreased the guide pins.

So as far a service manual goes, you're on your own for this job.  The
similarity to other brakes is enough that you can figure out most of it, but
you're going to have do without official published torque values.  The added
complexity of having to deal with retracting 2 pistons, the pad sensor
wires, and the spring clips that hold the outer pads to the carrier,
combined with the total lack of a published procedure lead me to feel that
it's not a good idea for somebody to do the S4's front brakes without having
a couple of previous disc brake jobs under their belt.

Wayne Dohnal
1994 S4