Handbrake on Audi A2 1.2Tdi

@1200TDI If you had to hammer the adjuster wedge SOMETHING IS SERIOUSLY WRONG. The little wedge is drawn down to progressively fill the gap in the mechanism as the pads and drums wear. It MUST be fitted the correct way round so that the teeth on one of the longer sides engage with the corresponding teeth on the leading edge shoe. As far as self adjusters for shoes go they are actually very good as long as they have been correctly installed. There is a little pin on the top of the adjuster to stop them being fitted the wrong way round, but can be defeated with a hammer.?.

This is what an adjuster wedge looks like and the teeth and pin can both be clearly seen.as can the location for the pull down spring...

1619011833468.jpeg
 
RAB said:
In my experience, the cables don't stretch but the springs at the wheel end get weaker with age
Click to expand...
The handbrake cables are new, yet no handbrake efficiency twice and 2 months/1200 Kms until I convince the adjusters with a (small) hammer, so not sure about that...
...or these new cables (not from AUDI) have worst springs than OEMs, a possibility, maybe that's it :).

This possibility confirm my advise, don't start to solve a weak handbrake by changing the cables !!
I'll check next time how the adjuster wedge are oriented but doubt I made the mistake 4 time in a raw.

audifan said:
If you had to hammer the adjuster wedge SOMETHING IS SERIOUSLY WRONG
Click to expand...
As I could not say where the problem was coming from, I install a complete set of drums, pads & springs from a retired Lupo 3L (newer parts), and I had the same issue until I read the comment from "steveb" here about weak adjusters and decide to look into this. And the hammer is just here because you cannot push these with your fingers, right.

The only common point between the original A2 & the Lupo are some surface oxidation on the parts.
A auto-adjusting mechanism that cannot handle the ageing (light surface oxidation) is a crap design and/or execution.

The bottom line is the advise to manually push these crap adjusters before to lose time & money elsewhere (here you have 0 chance to get the nipple wrong)
 
That is the whole point of these adjusters. The wedge is drawn down by the weak spring that hooks into the bottom of it. In all the cars I've worked on over the years this design of rear drum self adjuster is the best, Something must be wrong. You have swapped the drums "pads" and springs from your old Lupo but are the wheel cylinder working correctly or partially seized? Yes I have seen the adjuster fitted the wrong way round but did not imply that yours was fitted the wrong way round. Out of curiosity when was the brake fluid last flushed? Can the hand brake lever move inside the shoe or is it seized to the shoe? Have you checked the internal diameter of the drums is still within the wear limits? Are the cables for the hand brake correctly routed and secured as per the manual and free to operate? Can you take a couple of pictures of the installed shoes and springs in the hope that something may be spotted? How high is the hand brake lever when the brake is applied? How many clicks is the lever applied?

Are you sure the aftermarket cables on the car are suitable for the 1.2 tdi?
 
Are the new cables identical to the old? To protect the drums, there's not much movement of the shoes, so a small difference in length will make a huge difference in how well they work. Once installed, with the handbrake adjusted, press the brake pedal hard; this will adjust the wedges - no need for a hammer. If you require a hammer, assembly is incorrect or the cylinders aren't working.

RAB
 
It pass the MOT, and I only have 2 'clicks' before fully engage the handbrake, so I am done.
Will see next year.
 
audifan said:
2 clicks seams too tight to me. 4 clicks in the manual.
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That's for a normal A2! To prevent the aluminium drums from being distorted or even broken by excessive pressure, there's very little movement in the brake shoes on a 1.2Tdi and they run very close to the drum. Two clicks is about right if there's no binding. The drums are a composite of aluminium and silicon carbide, the latter making them very wear-resistant; with a standard (soft) set of brake shoes, my wife can wear the shoes out in about 5,000km! But they have the strength of aluminium!

RAB
 
Shouldnt all brake shoes have as close a tollerance to the drum, without binding to enable best service and parking brake??
 
RAB said:
In my experience, the cables don't stretch but the springs at the wheel end get weaker with age, which has the same effect as cables stretching. If the wedge doesn't self adjust, is it the wrong way around - there's a nipple at the top that should face outward? If you fit it the wrong way around it won't work!

Also there are only two suitable brake shoes, Zimmermann 10990.152.3 and VW/Audi 6E0 698 520X (actually made by Pagid but only available from VW/Audi). About £40 and £60 respectively but the Pagid set comes with everything except the cables. Don't waste your money on anything else as they'll be too soft!

RAB
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Hello RAB. You advise Zimmermann 10990.152.3 but the part website I use advise 10990.102.4 or 10990.100.3, who is right ? One is 180 mm, the website think it's 200 mm ! Sorry it's 180 mm, once again a website that do not distinguish the 3L...
 
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However I have a question, rear kit come with Brake wheel cylinders 15,87mm & 17,46mm with no indication on witch to use (both list A2 1.2TDI), what are the difference ?

Pads and Discs for AUDI A2 (8Z0) 1.2 TDI

Brembo offers a wide range of high-performance discs and pads for your AUDI A2 (8Z0) 1.2 TDI. Discover the catalogue!
www.bremboparts.com www.bremboparts.com
 
1200TDI said:
However I have a question, rear kit come with Brake wheel cylinders 15,87mm & 17,46mm with no indication on witch to use (both list A2 1.2TDI), what are the difference ?

Pads and Discs for AUDI A2 (8Z0) 1.2 TDI

Brembo offers a wide range of high-performance discs and pads for your AUDI A2 (8Z0) 1.2 TDI. Discover the catalogue!
www.bremboparts.com www.bremboparts.com
Click to expand...

The 1.2TDI uses rear brakes with build code 1KR.


drum brake		rear
180X30MM 4/100		PR-1KR
drum brake
back plate
wheel brake cylinder
brake shoe with lining		rear
180X30MM 4/100		PR-1KR

Rear brake wheel cylinder 1H0611053A
61H0 611 053 Awheel brake cylinder15,87 FAG2

Rear brake shoes 6E0698525 6E0698525X
12-136E0 698 5251 set: brake shoes with linings180X30MM1
12-136E0698525 X1 set: brake shoes with linings
Detail of the restored at the factory		180X30MM1

Rear brake drum 6E0609617
266E0 609 617brake drum180MM2

drum brake; back plate; wheel brake cylinder; brak... Audi A2 (A2) 2005 year Audi EUROPA 609010

drum brake<br/>back plate<br/>wheel brake cylinder<br/>brake shoe with lining Audi A2 (A2) 2005 year Audi EUROPA 609010 spare parts
audi.7zap.com audi.7zap.com
 
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1200TDI said:
However I have a question, rear kit come with Brake wheel cylinders 15,87mm & 17,46mm with no indication on witch to use (both list A2 1.2TDI), what are the difference ?

Pads and Discs for AUDI A2 (8Z0) 1.2 TDI

Brembo offers a wide range of high-performance discs and pads for your AUDI A2 (8Z0) 1.2 TDI. Discover the catalogue!
www.bremboparts.com www.bremboparts.com
Click to expand...
Brembo and others may claim to offer rear brake parts suitable for a 1.2Tdi but don't take their word for it. Most are intended for steel drums and are simply not hard enough. The composite drums on a 1.2Tdi will make short work of them. I only ever found two suitable sources, see above.

RAB
 
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