[team illuminata]

I was going to replace the rear brake line yesterday then this happened.

So I said F-it and went to the track instead. I did come back later and straightened my spool of exotic Audi brake line.

Need to make it look like this somehow:

I guess i'm going to need some new tools; and a new tool box.

 

[team illuminata]

Heavily invested in brake line tools now. Worked though. I just need some more brake projects to justify the investment.

I started at the master cylinder end and taped the new line to the old line as I went. The flare went well but I couldn't get the first bend as close to the fitting as the factory but it looks OE enough in my opinion.

I'm glad I replaced the rear brake line as it fell apart after it saw it's replacement and cried tears of brake fluid.

To my surprise it actually fir very well. I mean, it should right considering it was virtually a copy of the original. Things like this generally do not go this well for me though. I had to replace a few clips with new unfortunately.

Me bleedin' bleed nipples are bleedin' rusted to buggery in the rear and as I replaced the rear brake line I now have to bleed the buggers! #URQuattroFun

Later; I need a break from brakes. Next up: Transmission linkage stabilizer which is NLA, of course and then the hydraulic system.

 

[team illuminata]

Time to address the shift link stabilizer. Number 35 in this diagram. The plastic sockets on the ends wear and it is NLA (No Longer Available).

Mines a little loose so let's build a new one.

Now it's NPA (NO Problem Anymore)

 

[team illuminata]

Decided to take out the steering rack, hydraulic pump, accumalator and reservoir en masse. Seems as if every bit of it is leaking.


Steering rack

At brake master cylinder

Et voila!

Now what?

 

[Sepp]

I've done the same thing.
A lot of my hose ends were leaking.
I got new ones locally.

Best of luck!

 

[WAUOla]

Is that 811 622 10x part the master cylinder?

Just asking, as my Swiss WX'ed car came with 23,84mm accepting brake servo, and not the 25mm version as many other late urquattros.
So, it made me think about maybe the low power urquattros had the typ 81/85 setup with 23mm masters.

 

[team illuminata]

Is that 811 622 10x part the master cylinder?

Just asking, as my Swiss WX'ed car came with 23,84mm accepting brake servo, and not the 25mm version as many other late urquattros.
So, it made me think about maybe the low power urquattros had the typ 81/85 setup with 23mm masters.

No, that's actually the steering rack; the end that bolts to the inner wheel well.

 

[WAUOla]

No, that's actually the steering rack; the end that bolts to the inner wheel well.

I see! Do you know the setup of master cylinder on your car (23,84 vs 25mm) ?

It doesn't make sense Audi selling 25mm master for a special 23,84mm brake servo as only listed option under ur & Sport, and then tell that's not the corret part. :facepalm:

 

[team illuminata]

I see! Do you know the setup of master cylinder on your car (23,84 vs 25mm) ?

It doesn't make sense Audi selling 25mm master for a special 23,84mm brake servo as only listed option under ur & Sport, and then tell that's not the corret part. :facepalm:

I have no knowledge about the brake master cylinder on this car. I'm just happy I know where it is and it's not leaking.

Sorry.

 

[team illuminata]

My apologies, it's been a while since I have updated this thread and that's because it's been a while since I worked on the car. My wife's A3 booted the Quattro off the hoist a while back and I've since been too busy with the parts business to get it back on. Well that change this weekend when I found the hoist vacant along with my schedule. So on it went, again.

I am waiting for a friend to figure out how to replace the hydraulic hoses while using the original fittings so I thought I'd tackle bleeding the brakes which, of course required freeing up the rusted bleed nipples in the calipers. Well I only broke two off, left front and left rear!

How do I fix these? I imagine it involves removing the calipers which I managed quite easily on the left front but the left rear is fighting me. I managed to unhook the handbrake cable from the lever but the outer sheath looks like it's fused to the caliper in it's seat.

I'm also struggling to get the brake union on the inner fender separated.

I left them soaking in PB Blast overnight. Think that will work?

 

[team illuminata]

More progress but nothing picture worthy, sorry. I managed to free up both the handbrake cable and the brake line union yesterday but was less successful with the brake calipers. Unless you count that I was able to remove the rear caliper and place it on the bench that is.

So I cut a slit in the front caliper's bleed screw, or at least what was left of it. The stub was protruding about 4mm so there was quite a bit to work with. I had hit it with PB Blaster again when I got there so that had had an hour to soak in. I heated it as much as I could with a propane torch then with CFC Freeze Off and then heated again. I then hit it with my impact screwdriver and guess what? No, it didn't come right out; it broke right off flush with the caliper

Needless to say I didn't move on to the rear caliper.

So what's next, drilling it out and re-tapping, reverse drilling? New car?

 

[team illuminata]

I found a few hours to work on the car today. I basically pulled off more parts. Gotta start installing parts.

Tried EasyOut on one of the seized bleeders. FAIL

So turned my attention to the CIS injection system because you can never have enough parts on the floor.

Then started thinking about getting the downpipe welded back together. If you remember it separated after the engine stand let go and allowed the engine to rotate! This meant reassembling everything on the engine so I could mark the orientation which might be important.

 

[team illuminata]

SUCCESS! Las night, with a lot of help from my mein Freund Werner and some Rojo Red lubrication we drilled out the seized bleeder screws from the brake calipers.

We first established a pilot hole all the way through the bottom of the bleeder then chased that with a tap drill being carful to stop once we reached the end of the threads.

Because the tip of the bleeder was smaller than the tap drill it was left loose in the bottom of the hole and after cleaning out the threads was easily extracted.

Obviously a lot of debris found it's way into the piston chamber, especially as we cleaned out the other threads too, so we dismantled them with a view to giving them a thorough cleaning and any needed replacement parts. Right now they look to be in good condition though so I'll probably just reassemble them.

 

[team illuminata]

While waiting for parts to come in I decided it might be a good idea to take inventory of all the spare parts I already have and make a list. This was prompted by the realization that I have recently ordered parts that I already have in my collection of parts bins! Let the list making begin.

Used parts:

New parts: (yes, we sell Corbaeu seats)

Take offs (used to be on the car)

Turns out I have a lot of spare parts, 129 separate items if I include take offs and lumping together most of the removed AC stuff. I tried to figure out part numbers for everything and got pretty close. I did discover that about a dozen parts I inherited from the PPO (previous previous owner) aren't actually for a UR Quattro so that was good to know.

 

[WAUOla]

Nice progress!

Co-member of local Audi club mentioned rear calipers benefits from a lubrication nipple, to avoid so much PITA servicing needs on them.
If you're ever around it, could you check if you cylinder head is given 034 103 351 G or what? I need to continue projecting the 400hp 10V thingy...

 

[team illuminata]

Nice progress!

Co-member of local Audi club mentioned rear calipers benefits from a lubrication nipple, to avoid so much PITA servicing needs on them.
If you're ever around it, could you check if you cylinder head is given 034 103 351 G or what? I need to continue projecting the 400hp 10V thingy...

That would be for the handbrake mechanism right? I've seen that on another thread. My handbrake works well and the car will never see salt again so I'm going to leave it alone for now.

I'll try to remember to look at the head's part number next week.

 

[team illuminata]

Finally got my Unicorn clips from Germany. AKA actuator clips. I only need one but got a few spares.

All the bits needed to make the center diff actuate.

 

[team illuminata]

Installed

 

[team illuminata]

Nice progress!

Co-member of local Audi club mentioned rear calipers benefits from a lubrication nipple, to avoid so much PITA servicing needs on them.
If you're ever around it, could you check if you cylinder head is given 034 103 351 G or what? I need to continue projecting the 400hp 10V thingy...

Old head:

New head:

Hope this helps.

 

[WAUOla]

It sure does! Thanks a million. :thumbup:

Will also try to get hold of some basic info on Gr 4 and Gr B, and then we're talking machine planning.