How to Change the Rear Brake Pads on a 1989 Audi 200

When thinking of Audis, most people think of the luxurious and performance-oriented R8, TT or A4, with classic Audis falling by the wayside. The 1989 Audi 200 is one of those models. Compared with modern Audis, this sedan is neither stylish nor powerful, but when compared with luxury cars of its era, the roughly $34,000 Audi 200 was tops. Mechanically, the 200 was ahead of its time, standard-equipped with a 2.2-liter, turbocharged in-line five-cylinder engine that pumped out an impressive 162 horsepower and 177 foot-pounds of torque. It also came standard with four-wheel disc brakes, a rarity in the 1980s. Replacing the rear brake pads on this old-school luxury vehicle is a straightforward task that any experienced do-it-yourselfer can complete.

Instructions

1

Loosen the rear lug nuts with a ratchet and socket and raise the rear of the vehicle with a floor jack. Slide jack stands under the Audis rear cross member and lower the vehicle onto the jack stands. Remove the lug nuts and pull the wheels from the rear hubs.

2

Remove each of the two caliper bolts with a ratchet and socket while holding each bolts respective guide pin steady with a combination wrench. Pull the caliper from its bracket and hang it from a nearby suspension component using a bungee strap.

3

Slide the brake pads from the caliper bracket. Remove the two caliper bracket bolts, then pull the caliper bracket from the rear hub.

4

Pull the rotor from the rear hub. If the rotor will not pull off easily, lightly tap the rear of it with a rubber mallet to free it.

5

Inspect the rotor for any defects, including deep grooves, uneven wear, mirrorlike shine or evidence of grinding. If any defects exist, replace the rotor with a new one. Alternatively, if you have access to a micrometer, measure the thickness of the rotor and compare it to its minimum refinishing thickness of 0.335 inches. If it is at least that thick, have a machine shop or auto repair shop resurface the rotor.

6

Slide the original or new rotor onto the rear hub and position the caliper bracket back on the rear hub. Hand-thread the caliper bracket bolts, then tighten them to 48 foot-pounds with a torque wrench and socket.

7

Insert new brake pads into the caliper bracket.

8

Remove the caliper from the bungee strap and find the Allen key-shaped hole in the center of the caliper piston. Using a ratchet, a 6-inch socket extension and an Allen-bit socket, turn the caliper piston clockwise while pushing the piston toward the caliper body until the piston inserts completely into the calipers bore.

9

Set the caliper on the bracket and hand-thread new caliper bolts into the caliper. Tighten the caliper bolts to 26 foot-pounds, using a torque wrench and socket, as you use a combination wrench to keep each bolts respective guide pin from turning.

10

Repeat steps 2 through 9 to replace the brake pads on the other side of the Audi.

11

Install the wheels back onto the rear hubs and hand-tighten the lug nuts. Raise the 200 off the jack stands, using a floor jack, then remove the jack stands. Lower the Audi to the ground and tighten the lug nuts to 90 foot-pounds with a torque wrench and socket.

12

Press and release the brake pedal until it feels firm, then check the fluid level in the 200s master cylinder reservoir. If the fluid level is not at the Max line, unscrew the cap from the master cylinder reservoir and add DOT 4 brake fluid until it reaches the Max level, then tighten the cap.