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TDI 101 Got a simple/basic TDI question? Are you a newbie (new to the forums). Feel free to post your question here.

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Old October 11th, 2006, 14:21   #1
PseudoFinn
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Default Pistons won't wind back on rear calipers...

So I loaned my TDI to someone... someone who will never be loaned a vehicle again- and they royally screwed my rear brakes up. It took quite a while to remove the calipers, as they were locked up, to replace the rotors. While attempting to wind back the caliper piston... I realized I was not getting anywhere. They would wind, but the booting never compressed, and the piston never went back in, even after maybe 20-30 revolutions, they never seemed to move. Is it possible that the piston was so far extended that they simply will not go back in now? I'm having this problem on both sides. Am I now out 200 dollars for new calipers, or can they be repaired. Am I correct in assuming that when I start turning the piston, it should go right back in without many revolutions?

Please help! My car is now sitting in a parking lot, 30 miles from home!
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Old October 11th, 2006, 14:26   #2
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how did they trash your rear brakes so fast?
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Old October 11th, 2006, 14:36   #3
MOGolf
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What tool are you using for the windback? Does it also put pressure on the piston at the same time?

If it does get pushed out to the extreme limit (e.g. you have no pad material left) it does take an extreme amount of pressure to get it started back in.

There are several people in MI that can help. Can you supply a more specific location for the car?
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Old October 11th, 2006, 14:36   #4
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It was a fairly extended loaner... didn't expect it to be.... but it was.

Not something I will do again. Family or not.
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Old October 11th, 2006, 14:39   #5
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ah. bummer. i haven't had to do rear brakes yet, so i am useless. i do know there are some special tools which are necessary. maybe you need one of those? just wild assed guess, fwiw
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Old October 11th, 2006, 14:40   #6
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Do you have the brake fluid reservoir open?
IF its full, The fluid needs somewhere to go when you push back the piston.
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Old October 11th, 2006, 14:42   #7
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4Gman.... I cracked the fluid reservoir. No luck.

MOGolf... The vehicle is currently located in Linden, MI. I didn't realize I would need to apply much pressure at all. This is encouraging. Any idea what kinda tool I would need to get my hands on to get the job done?

Thanks for the SUPER speedy replies, everyone!!
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Old October 11th, 2006, 14:51   #8
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i think you need this thing

http://www.tdiparts.com/catalog/prod...roducts_id=402
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Old October 11th, 2006, 14:51   #9
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You might need to apply pressure with a large c-clamp while turning the piston. I bought the Lisle universal tool from Sears for $12

How far is the car from these guys?
http://www.steveseuropeanauto.com/ab...e/SEA_shop.htm
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Old October 11th, 2006, 14:58   #10
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If the piston locked up - you would be wise to replace or rebuild which ever you inclined to do. Kits are cheap but you must prepare cylinder and the piston. If they can be, when you disassemble you know what is required.

Bleed the sys well, if you do not have a work shop manual you should get or borrow.
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Old October 11th, 2006, 15:05   #11
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If you can carefully drive it to near Fowlerville, JETaah might be able to help. http://www.martinbergelllc.com/
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Old October 11th, 2006, 16:34   #12
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LOL, you have to have the right tool for the right job...Shortcuts just make the journey longer.

www.metalnerd.com

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Old October 11th, 2006, 20:03   #13
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If there is an Autozone in the area they will charge you $0 to loan you the tool. You do have to pay $35 upfront but you get it back when you return the tool.
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Old October 11th, 2006, 20:44   #14
GoFaster
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I've done it with the standard cube-shaped tool on a ratchet with a big adjustable woodworker's clamp around the whole deal. Turn a little, squash a little, turn a little, squash a little, etc. It's a whole lot easier with the tool designed for this purpose.
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Old October 11th, 2006, 21:39   #15
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rear brakes don't do all that much if you aren't hauling ass. if they aren't totally locked up, drive it home and turn up the stereo so you don't have to listen to the griiiiinding.
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