4AudiQ

I started investigating doing a BBK - Rears in the Fall of 2006 and compared products, procedures, hardware, everything I could read and study about upgrading the rear brakes. I finally decided to go with Alex at STaSIS since he helped me out so much with my front BBK.

<img src="http://pictureposter.audiworld.com/81050/img_1462.jpg">
Here is why I wanted to go to a BBK - Rears; they are so much bigger than stock!
That is an S2 245mm x 10mm on the left and STaSIS 298mm x 20mm on the right!


I started collecting the parts to do the BBK - Rears in January 2007. Since STaSIS did not have anyone they knew of who had done an install with their Kit on a B4 Audi, I had to solve one problem after another. It took from January to May to solve each of the problems I encountered.

<img src="http://pictureposter.audiworld.com/81050/img_1474.jpg">
1. The first parts I needed were 2000 Audi S4 rear calipers with parking brakes. I ordered a set from a junk yard and I test fitted these along with a 2000 Audi S4 rear rotor onto my setup(1 year ago I had swapped out my 4 lug hubs for 5 lug hubs). In the process of test fitting these on my car, I realized I needed to off-set the rotor somehow.

<img src="http://pictureposter.audiworld.com/81050/img_1464.jpg">
2. I finally figured out I had to move the rotor toward the outside of the body by 8mm. I settled on putting an 8mm spacer in between the axle face and the inside rotor hat.

<img src="http://pictureposter.audiworld.com/81050/img_1465.jpg">
I started with 8mm thick wheel spacers made from 6061 Billet Aluminum/Magnesium alloy CNC'ed (which I purchased) with dimensions of: 155mm Outside Diameter and Center Bore Diameter of 57.1mm. I machined that down to: Outside Diameter of 132 mm and a Center Bore of 74 mm.
<img src="http://pictureposter.audiworld.com/81050/img_1473.jpg">
Here you can see the 8mm spacer (silver in color), between the axle face &amp; the inside of the rotor hat.

3. Now that I knew the S4 Calipers were going to work, I ordered a re-manufactured set of complete 2000 Audi S4 Rear Brake Calipers.

4. I ordered Speed Bleeders for the rear calipers so that I could bleed the brakes by myself.

<img src="http://pictureposter.audiworld.com/81050/img_1459.jpg">
5. I then ordered the STaSIS Rear Brake Kit (STaSIS Part #KB01.5001.00)
2 - Alcon Rotors, 298mm x 20mm, vented, gas slotted
2 - STaSIS Rotor mounting hats, directionally vented
2 - STaSIS Carrier mounting brackets
1 - set Ferodo DS2500 brake pads
(FCP541H)-not shown
All the associated hardware &amp; bolts.


<img src="http://pictureposter.audiworld.com/81050/img_1457.jpg">
5. During several test fittings of all the parts and pieces, I realized I needed to order custom Stainless Steel lines, with 1 end a banjo fitting.

<img src="http://pictureposter.audiworld.com/81050/img_1478.jpg">
Here you can clearly see the banjo fitting on the caliper in position.

6. I then bead blasted the calipers and painted them black with high-temp brake caliper coatings from Eastwood.

<img src="http://pictureposter.audiworld.com/81050/img_1468.jpg">
Here you can see one of the Carrier mounting brackets(gold colored metal).

7. I replaced the front Hawk HPS pads with Ferodo DS2500 pads.

8. When I went to install the right rear caliper, I realized there was a problem with the re-manufactured caliper because I could not get the piston to move in. I ordered a replacement and installed it when it came.

<img src="http://pictureposter.audiworld.com/81050/img_1482.jpg">
This picture shows the difficulty in getting to the parking brake adjusting nut.
9. To get to the parking brake adjustment, I dropped my exhaust system, heat shields, and even the 1 piece drive shaft I had installed in February.

9. I bleed the entire brake system using the new Speed Bleeders, which allows me to bleed the brakes the old fashioned way of pumping the pedal, and doing the whole job myself, with no helper needed.

10. I then bedded in the pads &amp; new rear rotors.


<img src="http://pictureposter.audiworld.com/81050/img_1485.jpg">
Completed right side with unpainted caliper.

<img src="http://pictureposter.audiworld.com/81050/img_1486.jpg">
Completed left side with painted caliper.

So, how does it brake?
Better than before, but I have not gotten into a tight situation to really test them out. In my final runs of bedding in the pads &amp; rotors, I really jumped on the bakes and it slowed down very rapidly. Brake bias does not seem to be affected, even though the rears are almost as big as the fronts (S6 V8 Front Rotors 314 x 30).

dragon-ryder

You've really impressed me with the work you've done on your B4, not too many others put the time and effort in to do it right. Outstanding Job!

|skolnick

Instead of the spacer you can use an S4 rear hub.

ryoung

... that 298mm rotor doesn't look quite as large when it's sitting in a 20" wheel. Besides the rotor and hat, all I needed was the S4 carrier for a simple install. BTW: I thought that rotor is 298x20 rather than 298x22.

<img src="http://pictureposter.audiworld.com/17157/acid1b.jpg">

450exc115

I take it you are using S2 rear hubs for the conversion and that is why you needed the spacer?

4AudiQ

They were installed last summer by Ron Wood of VW Specialties.

4AudiQ

You are correct on the 20mm width of the rotor. I checked the paper work that came with the Kit and sure enough, it says 20mm. I stand corrected. Thanks for pointing that out.

4AudiQ

Could it be that "Sport" option of our cars that seems to drive us to do great work on them?
Maybe we should start a club for
"1995 Audi Sport 90 Quattro's".
I wonder how many of us "Sports" read this forum?
You seem to bitten by that same bug that I have.

450exc115

I thought so.. I have a full 01 S4 setup on the bench to do the 5-lug swap including brakes and rotors.. Just need to remove the axles and put new wheel bearings in.. I fully expect to see the 8mm offset but with the new 17" rims with an et45 I will only be 6mm wider.. I can live with that!

Oh and even a 96-01 A4 rear hub will do the trick without the needing a spacer as it is the same as the S4 hubs.. I just lucked out and got the whole assembly with brakes.

Looks great!!

Tom

dragon-ryder

My daily driver is the Pearl 90CS in my sig, auto, electric seats, far from the sport model. BUT, I'm changing that, I picked up the sport model recently and plan on swapping all of the sport goodies into the CS, including a rebuilt 5spd. We're definately bitten by the same bug but I don't think it's because of the sport designation.