help needed sourcing rear caliper carriers

S

stevebootes

Member
Hi everyone, been a while since I've been on here and typically it's only when I want something ;-)

Our 2004 TDI 90 A2 is currently at our local VW specialist having its MOT, which it's failed on (amongst other things) rear brakes binding.
We initially assumed it was just seizing calipers (we're on our third set I think) but apparently this time is different - it's the caliper carriers that have rusted pretty badly, stopping the caliper sliding nicely. The garage ordered replacement carriers from TPS but when they turned up they didn't fit - they were the wrong offset. Thinking they'd sent the wrong set they ordered some more and they were exactly the same. Apparently there's only one part number for the caliper carriers listed and no revisions, so it's not like they can try something else.

That's where you come in - has anyone seen this sort of thing before? Does anyone know of any other part numbers that we might be able to try? I'm assuming they're VW Polo parts originally (as many other bits on the car are) but I don't want to take a guess without someone who knows more than me pointing me in the right direction.

Please help us to bring our A2 home where it belongs!
 
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have a look at thishttps://www.ebay.co.uk/itm/For-Audi...916509&hash=item2ce6a7d2b4:g:DHoAAOSw9P1cf-it
54665
 
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Andrew said:
Hi,

A quick look, and your garage is correct, only one part number, item 2...

floating caliper brake; brake caliper housing; bra... Audi A2 (A2) 2003 year Audi EUROPA 615060

floating caliper brake<br/>brake caliper housing<br/>brake carrier with pad retaining pin<br/>brake disc<br/>brake cable Audi A2 (A2) 2003 year Audi EUROPA 615060 spare parts
audi.7zap.com audi.7zap.com

Is this part number on the new 'wrong' carrier?

Andy
Click to expand...

That's part of the problem I think, the old carriers are so rusty they can't make anything out.
EDIT - Oh, mis-read this, you're asking about the NEW carrier, I'll ask..
 
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I've just spoken with the garage again and they're completely stumped. The carriers they have have the wrong offset and they only thing they can suggest is having the carriers machined so that it corrects the offset. It's almost like the rear brakes have been changed at some point for something else. Though the disks and the calipers (both new parts) fit fine using the old carriers, so it's almost like the whole rear axle assembly has been replaced with something different at some point. Really weird!
Anyone have any bright ideas?
 
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It does seem something non standard has been fitted.

Some suggestions...

Is it possible to read the part number on the caliper? Just wondering if you could google it for information and work backwards to track down matching carriers.

I would put some effort into cleaning up the original part to try and read the part number. I know you said it is very rusty but I would be surprised if you could not read it eventually. Chemical rust removers work really well, I used a product called Rust Buster (I think) but that takes a long time (days) and not much help to you but you will be amazed with the results.

I know it is an expenditure, but not that great, and fit new correct calipers to go with the correct carriers or is it so non standard this would not work?

Andy
 
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The brake disks and calipers have already been replaced with brand new units from TPS and fit perfectly when using the old carriers. That's the first thing they replaced when they found the offset was wrong. We've confirmed the part numbers and they're all correct.
The only thing I can think is that either the stub axle or the hub assembly is non-standard, can't think of anything else that would affect the offset but still allow the "proper" calipers, disks and pads to fit.

I'm going to see if I can take a look at the old carriers - ideally to try and get a part number, but if nothing else to measure the offset and compare it to something else.
 
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stevebootes said:
The brake disks and calipers have already been replaced with brand new units from TPS and fit perfectly when using the old carriers. That's the first thing they replaced when they found the offset was wrong. We've confirmed the part numbers and they're all correct.
The only thing I can think is that either the stub axle or the hub assembly is non-standard, can't think of anything else that would affect the offset but still allow the "proper" calipers, disks and pads to fit.

I'm going to see if I can take a look at the old carriers - ideally to try and get a part number, but if nothing else to measure the offset and compare it to something else.
Click to expand...

Does sound like major changes have occurred. Wonder if the entire axle has been swapped for a 75TDI axle which can create problems as Steve Birchall discovered when he wanted to swap from drums to rear discs. Maybe a former garage overcame these problems somehow to leave your non standard arrangement.

Good luck, it's a real puzzle. - Andy
 
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That's an interesting thought. I have looked on eBay and found someone fairly locally (same county at least) with a disc-based rear axle, I'm getting to the point where that might be the easiest way out!
I'd be interested to know what issues Steve Birchall had - I'll see if I can find that thread.
 
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Some history on rear axles and link to a disc brake conversion in post 12 -

Swapping 1.4 TDi rear axle for 1.6 FSi rear axle with disks

Fed up of my rear drums and was wondering about a rear disk upgrade, I know it's not a performance upgrade, it's more cosmetic and pleasing. I have an axle from a 1.6 FSi available with disk brakes, looking at ETKA/Elsa they seem identical and the rear axle doesn't seem too hard to swap...
www.a2oc.net

Another option would be to try one of Phil Wards de-rusting methods. You may be able to read the part numbers even if the bracket is not servicable -

Remove rust (without using abrasives).

I've owned a classic mini for 35 years and in that time I've learnt a thing or two about removing rust. I tend to prefer not to use abrasives as abrasives remove good metal along with the rust. The methods I will describe in this thread are: Citric acid Brick acid Phosphoric acid Molasses...
www.a2oc.net

Cheers Spike
 
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Found what I remembered but I was wrong about the context, sorry, seems a mistake on Steve's part but might be still worth a read.

Changing from rear drums to discs.

Hi I need sone help from people who have successfully completed this conversion, please!!!! I bought an axle from a 1.6 FSI and bought new parts for everything. (And I mean everything.) My mechanic was about to rebuild the axle but is telling me that most of the parts I bought don't fit ...
www.a2oc.net

Andy
 
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