595 Installation instructions in combination with the 302x12 brake disc on the Audi Quattro Typ 85/ Audi S2 Coupe

Installation instructions Audi Quattro Typ 85/ Audi S2 Coupe

Our customer Nico has installed our adapter article 595 on his Audi Quattro Type 85 in combination with the brake disc 302x12 mm GD1519 and his original brake calipers. He wrote a great installation guide and great photos. Here you can find out how to proceed step by step.
Many Thanks to Nico for his great support.

Please note

Please read these instructions carefully before starting work. If the conversion is too difficult for you, please commission a specialist garage to carry out the installation. We cannot accept any liability for consequential damage caused by improper installation. Correct installation and adjustment saves time, costs and trouble

Disassembly:

Old brake system (brake disc, brake caliper and brake caliper carrier)
Remove or process the air baffle or brake baffle or anchor plate (we prefer removal, as the ventilation of the brake is better ensured). !!!Important!!

!!Important!!

It is essential to check that there are no rust or paint residues on the bolt-on points of the steering knuckle or wheel hub. If this is the case, please clean them. Then check the threads of the steering knuckle for damage.

What do you need to do that?

Depending on your technical knowledge, about 1-2 hours of time
Torque spanner with suitable attachments
Liquid threadlocker

First, a comparison of the old and the new brake disc

Here you can see the original brake caliper of the Audi Quattro Type 85/Audi S2 Coupe, which is bolted to the suspension strut from the outside. Please note, this Epytec tuning adapter is bolted from the inside.

The contact surface must therefore be thoroughly cleaned. (see photos below)

Especially with powder-coated struts, make sure that the contact surface is bright.

After removing the adapter, make sure that the brake hose is not kinked or excessively stressed. (Hang the brake caliper up on the suspension strut)

The Epytec tuning adapter for the Audi Quattro Type 85/Audi S2 Coupe is then mounted using the original screws.

The wheel hub must then be free of rust in the area of the contact surface of the brake disc. The best way to do this is to take a wire brush and remove rust from the wheel hub. Alternatively, a Dremel can also be used.

Then fit the new brake disc and mount it with two or three wheel bolts so that it is clean and tight.

(Make sure that the wheel bolts do not damage anything on the inside, as they are of course screwed in deeper due to the missing rim).

The clearance of the new brake disc and the Epytec tuning adapter on the Audi Quattro Type 85/Audi S2 Coupe can now be checked.

The distance between the adapter and the brake disc can now be measured at the upper and lower edge.

This ensures that the brake caliper is correctly aligned with the brake disc and that everything lies flat. If it does not lie flat, remove the adapter again and clean the contact surface again or place the adapter underneath.

The brake caliper must now be turned back and pressed with the aid of a resetter (due to the integrated handbrake function, it cannot be reset without turning)

!!Tip!!

Make sure that the storage container does not overflow.

The original brake caliper of the Audi Quattro Type 85/Audi S2 Coupe can now be fitted to the adapter using the screws supplied.

It can happen that it cannot be fitted. If this is the case and the brake disc rubs slightly against the caliper, it must be machined slightly (see next point)

The original Audi S2 Coupe brake caliper must be ground down by just under 1 mm on the outer side.

It is important that the adapter moves freely

When everything moves freely, disassemble everything again and finally fit the adapter with thread locker and the specified torque.

Apply brake paste sparingly to the sliding points of the brake calipers or pads (copper paste, however, not for aluminium calipers) and ensure that the friction surface is not dirty, as this would significantly impair braking performance.