B8 A4/S4 Installation Guide - STaSIS

STāSIS Engineering
Signature Series Vehicles
B8 A4/S4 Installation Guidelines

Table of Contents
Page
Torque specs 3
Suspension
Front and Rear Suspension, Touring 4
Front and Rear Suspension, Challenge 12
Rear Anti-Roll Bar 25
Differential
Manual Transmission Center
Differential
30
Exhaust 35
Exhaust Kit
Braking
Monobloc Brake Kit 38
Bed-In Procedure 43
Post Installation Checklist 44
Page 2 of 44

B8 A4/S4 TORQUE VALUES
Suspension and Wheels
Front damper to upper mount
37 ft-lbs
Front damper upper mount to body
56 ft-lbs
Front damper fork pinch bolt 30 ft-lbs +
180º
Front damper fork to lower link
66 ft-lbs
Upper link pinch bolt
29 ft-lbs
Rear damper to upper mount
26 ft-lbs
Rear damper upper mount to body
37 ft-lbs
Rear damper to upright
111 ft-lbs
Rear sway bar link to lower control arm
30 ft-lbs
Rear sway bar link to sway bar
30 ft-lbs
Rear sway bar mounts
19 ft-lbs
Wheel spacer bolts
90 ft-lbs
Wheel lug bolts
90 ft-lbs
Brakes
Rotor set screw
48 in-lbs
STaSIS Challenge bracket to upright
92 ft-lbs
STaSIS Challenge caliper to bracket
70 ft-lbs
Brake line to caliper
14 ft-lbs
Exhaust
Down pipe to mid pipe slip clamp
17 ft-lbs
Hangers to body
17 ft-lbs
Mufflers to mid pipe
17 ft-lbs
Muffler adjustment bracket
17 ft-lbs
Center Diff
Torsen housing to transmission (short bolts) 7 ft-lbs +
90º
Torsen housing to transmission (long bolts)
18 ft-lbs
Tunnel crossmember to transmission mount
15 ft-lbs
Tunnel crossmember to body
41 ft-lbs
Driveshaft to output flange
30 ft-lbs
Drive shaft heat shield
18 ft-lbs
Tansmission drain plug
30 ft-lbs
Page 3 of 44

A4/S4 Suspension, Touring
Touring Suspension Kit
Parts List
Qty Description Part Number
1 Stasis Touring Spring Kit SP04.0005.00
Special Tools Required
Qty Description Part Number
1 Torque Wrench VAG 1331
1 Torque Wrench VAG 1332
1 Engine/transmission jack VAG 1383 A
1 Spring Compressor VAG 1752/1
1 Spring holder VAG 1752/7
1 Rear Spring Compressor VAS 6274
1 Supplementary Set VAS 6274/10
1 Hollow Piston Cylinder VAS 6179
1 Spreader 3424
1 Tensioning strap T10038
Please read ALL instructions prior to attempting installation. Please torque all fasteners to
specifications.
Page 4 of 44

Front Removal and Install
1 Before removing any parts, park the car on a secure, stable, and level surface. Remove wheel trim; pull
trim cap off light-alloy wheels (using puller in vehicle tool kit) and loosen (but do not remove) the wheel lug
nuts. Jack the vehicle up, and place the car on four stable jack stands or use a professional vehicle lift. We
recommend having two people available for certain steps of the installation.
2 Remove wheels
3 Before removing left suspension
strut, remove headlight range
control link from track control link.
(2009 and older)
4 Remove the fastener and plastic
nut on the inside of the fender lip.
This is to provide additional
clearance for the tires. The clip
will not be reinstalled.
5 Remove pinch bolt for upper
control arms. Remove both
joint pins in upper control
arms from wheel bearing
housing. The slits in wheel
bearing housing must not be
widened using a chisel or
similar tool!
Page 5 of 44

6 Disconnect the bolt that connects
the swaybar link to the damper
fork. Bolt can remain on swaybar
link.
7 Remove bolts that connect
damper fork to lower link and
damper. Use spreader (Audi Tool
# 3424 or equivalent) to remove
fork from damper. Pull bearing
housing down to gain enough
clearance to remove fork.
8 Perform these steps on both
sides of the car and then open
the front hood to reach the bolts
that hold the upper mount.
9
Unclip plenum chamber covers-1
& 3 - and remove them.
Page 6 of 44

10 Remove nut - 1 - . Remove filler
neck - 3 - with filler tube from
washer fluid reservoir and body
opening - arrow B - .
11 Remove nuts - arrows - , move
coolant reservoir upward and lay
it aside to access the mounting
bolt.
Do not disconnect any coolant
lines, reservoir does not have to
be removed.
12 Remove bolts - arrows - and
remove suspension strut with the
mounting bracket.
Remove similar bolts from
passenger side and remove
passenger side suspension strut
with the mounting bracket.
13 Remove OEM damper and spring
from upper mount.
Page 7 of 44

14 Remove OEM bumpstop and trim the large
end of the bumpstop to achieve an overall
length of –
2 ¾ inch
**NOTE**
If bump stop length within ¼” of 2 ¾”, no
need to modify
15 Reinstall bumpstop and replace the OEM
spring with the Stasis supplied spring.
*Note*- Bumpstop will no longer capture
on the damper shaft and will sit on the
damper body.
16 Reassemble damper assembly to the
upper mount and reinstall complete
assembly. Installation is the reverse of the
removal steps.
*Note*- Bonded rubber suspension
bushings can only be turned to a limited
extent. All mounting bolts of the
suspension links must only be tightened
when the suspension is compressed to the
curb weight position.
Page 8 of 44

Rear Removal and Installation
1 Remove wheel
2 Remove cover over lower damper bolt, then
remove lower damper bolt (21 mm).
Remove the two fender liner clips one either side
of the damper (#2) by gently prying upwards on
the open end of the clips.
Pushing the fender liner out of the way, remove
upper damper bolts (#1 16 mm) and remove the
damper by dropping straight down through the
opening in the lower control arm.
**S4 vehicle**
Remove ride sensor lever arm to prevent
damage. Located on rear control arm, driver’s
side.
*Make sure to reconnect during installation*
Page 9 of 44

3 Remove upper mount from damper and set
aside.
4 Remove OEM bumpstop and trim the large end
of the bumpstop to achieve an overall length of –
4 3/8 inch
**Note**
If bump stop length within ¼” of 2 ¾”, no need to
modify
5 Remove rear coil springs with spring compressor
tool VAS 6274 and VAS 6274/10.
Page 10 of 44

6 Install STaSIS rear spring with the spring
compressor. Progressive coils towards the top.
7 Install damper assembly and torque to:
Upper bolt: 37 ft-lbs
Lower bolt: 111 ft-lb
Note –
Bonded rubber suspension bushings can only be
turned to a limited extent. The mounting bolts of
the suspension links must only be tightened
when the suspension is compressed to the curb
weight position.
8 Install wheels and tighten. Lower the car onto its wheels and torque all wheel lug bolts to the recommended
torque.
Note: Check wheel alignment after suspension installation
Page 11 of 44

A4/S4 Suspension, Challenge
SL Suspension Kit
Parts List
Qty Description Part Number
2 Front Damper B8 A4 SA02.2501.00
2 Rear Damper B8 A4 SA02.2511.00
2 Front Springs SP03.1070.00
2 Front Upper Spring Mount SA10.0007.01
2 Rear Springs SP02.6040.00
2 Rear Spring Tenders SP03.0003.00
2 Rear Spring Tender Coupler SP03.0002.00
2 Rear Perch Male SA01.3018.00
2 Rear Perch Female SA01.3019.00
2 UHMWPE Spring Washer SA10.0001.00
2 Rear Spring Perch Spacer SA02.3510.00
2 Perch Wrench SA01.3001.00
2 Front Nylock Nut M12 HA03.0107.00
2 Rear Nylock Nut M10 HA03.0120.00
2 Rear Spacer Bolt M8 HA01.0806.00
2 Rear Spacer Washer M8 HA02.0802.00
Special Tools Required
Qty Description Part Number
1 Torque Wrench VAG 1331
1 Torque Wrench VAG 1332
1 Engine/transmission jack VAG 1383 A
1 Spring Compressor VAG 1752/1
1 Spring holder VAG 1752/7
1 Rear Spring Compressor VAS 6274
1 Supplementary Set VAS 6274/10
1 Hollow Piston Cylinder VAS 6179
1 Spreader 3424
1 Tensioning strap T10038
Please read ALL instructions prior to attempting installation. Please torque all fasteners to
specifications.
Page 12 of 44

Front Removal
1 Before removing any parts, park the car on a secure, stable, and level surface. Remove wheel trim; pull
trim cap off light-alloy wheels (using puller in vehicle tool kit) and loosen (but do not remove) the wheel lug
nuts. Jack the vehicle up, and place the car on four stable jack stands or use a professional vehicle lift. We
recommend having two people available for certain steps of the installation.
2 Remove wheels
3 Before removing left suspension
strut, remove headlight range
control link from track control link.
4 Remove the fastener and plastic
nut on the inside of the fender lip.
This is to provide additional
clearance for the tires. The clip
will not be reinstalled.
5 Remove pinch bolt for upper
control arms. Remove both
joint pins in upper control
arms from the wheel bearing
housing. The slits in the
wheel bearing housing must
not be widened using a chisel
or similar tool! This can
cause the pinch arms to
crack. If the control arm pins
are stuck in the housing, tap
lightly with a rubber mallet on
the bottom of the control
arms.
Page 13 of 44

6 Disconnect the bolt that connects
the swaybar link to the damper
fork. Bolt can remain on swaybar
link.
7 Remove bolts that connect
damper fork to lower link and
damper. Use spreader (Audi Tool
# 3424 or equivalent) to remove
fork from damper. Pull bearing
housing down to gain enough
clearance to remove fork.
8 Perform these steps on both
sides of the car and then open
the front hood to reach the bolts
that hold the upper mount.
9
Unclip plenum chamber covers-1
& 3 - and remove them.
Page 14 of 44

10 Remove nut - 1 - . Remove filler
neck - 3 - with filler tube from
washer fluid reservoir and body
opening - arrow B - .
11 Remove nuts - arrows - , move
coolant reservoir upward and lay
it aside to access the mounting
bolt.
Do not disconnect any coolant
lines, reservoir does not have to
be removed.
12 Remove bolts - arrows - and
remove suspension strut with the
mounting bracket.
13 Remove OEM damper and spring
from upper mount.
Note: You will not reuse the OEM
bumpstop, the thick washer, and
the nylock nut that sits on top of
the damper shaft.
Page 15 of 44

14 Remove swaged aluminum upper
spring seat retainer. Use a small
chisel and hammer to bend over
the swaged lip. A die grinder can
also be used to grind the lip off of
the center of the aluminum
retainer.
15 Install spring with delrin upper
mount onto the STaSIS damper.
Install upper cradle and rubber
upper mount onto the damper
assembly. Hold upper damper
pin in between the cradle and
mount with a wrench while
tightening the nut for the damper
pin to the rubber upper mount.
Tighten nylock nut to 37 ft-lbs.
CAUTION – DO NOT grab the
damper shaft with any tools while
tightening the nylock nut.
NOTE – Spring assembly will be
loose at preset perch height. This
is normal and will get loaded once
installed in the vehicle.
Page 16 of 44

16 Installation is the reverse of
removal.
Once the damper is installed
check that the spring perch is set
at the proper installed height, as
shown in the picture. The
Dimension should be 76mm from
the top of the cylinder head
(yellow mark) to the bottom of the
locking coil ring.
Before compressing the
suspension, confirm that the
upper urethane spring mounts are
properly seated on the springs,
the springs will self center onto
the cradle once the suspension is
compressed.
Note: Bonded rubber suspension
bushings can only be turned to a
limited extent. All mounting bolts
of the suspension links must only
be tightened when the
suspension is compressed to the
curb weight position. This can be
done by jacking up the wheel
while the car is on the lift.
17 Install Wheel and tighten
Note – do not fully tighten bolts
until car is at ride height.
Page 17 of 44

Rear Removal
1 Remove wheel
2 Remove upper damper bolts. Then
remove lower damper bolt and
remove damper.
Note: Discard the lower bolt cover.
It will not be reused.
*S4 Vehicle*
Remove ride sensor lever arm to
prevent damage. Located on rear
control arm, driver’s side.
*Make sure to reconnect during
installation*
Page 18 of 44

3 Remove upper mount from OEM
damper and set aside.
Note: It will be reused when
installing the STaSIS damper.
4 Insert pry bar between upright and
lower control arm (see picture) and
push down to relieve tension from
spring. You may need assistance to
remove the spring while you are
pushing the suspension down.
5 Remove the OEM lower rubber
spring mount, it will not be reused.
Note: You may remove the stone
guard to make it easier to make
height adjustment, however this is
not a requirement.
Page 19 of 44

Rear Installation
6 Install STaSIS lower spring perch
onto lower control arm and secure
with the supplied bolt.
Note: Check that the perch is set
to the proper installed height. As
shown in the picture below.
The dimension should be 64mm
from the bottom of the rear spring
perch spacer to the spring seat
(yellow mark). DO NOT include
the UHMWPE washer thickness
in the measurement.
Page 20 of 44

7 Install STaSIS spring and OEM
upper rubber mount. Earlier kits
include a tender spring with a
coupler on top of the main spring.
Note: You will have to use a pry
bar in the same manner used to
remove the OEM spring
8 Install the OEM upper damper
mount onto the STaSIS damper.
Grab cylinder head with a wrench
and tighten nylock nut to 37 ft-lbs.
9 Install damper assembly and
torque to:
Upper bolt: 37 ft-lbs
Lower bolt: 111 ft-lb, longer bolt
spacer goes against the upright,
short spacer between the bolt
head and damper end eye.
Note –
Bonded rubber suspension
bushings can only be turned to a
limited extent. The mounting
bolts of the suspension links must
only be tightened when the
suspension is compressed to the
curb weight position. This can be
done by jacking up the wheel
while the car is on the lift.
Page 21 of 44

10 Install wheels and tighten. Lower the car onto its wheels and torque all wheel lug bolts to the
recommended torque.
Check ride height – See next page
STaSIS recommended ride heights-
Front - 13 1/2” from the center of the wheel to the fender lip
Rear - 13 3/8” from the center of the wheel to the fender lip
Note: Check wheel alignment after suspension installation
Rev. 1 11/2/08
Page 22 of 44

STaSIS Signature Line Ride Height Adjustment
Ride height inspection and adjustment procedure:
1. After completing installation of the kit, set the vehicle on the ground and drive the car around the block
to settle the suspension. To take ride height measurements MAKE SURE THE VEHICLE IS PARKED
ON A LEVEL SURFACE. VERY IMPORTANT!
2. Measure the ride height of the vehicle at four points for future reference. Measure from the center of the
wheels to the bottom of the fender lip.
3. If you are pleased with this ride height then you are done, save the measurements for future reference.
If not continue to step 4.
4. Calculate the difference between the actual ride height and the ride height you would like the car to sit
at for the right front wheel. For optimum handling we recommend this be done with the driver in the car
and ¾ of a tank of fuel. We recommend that the distance between the center of the wheels and the
bottom of the fender lip is not set below 13.0 inches. The suspension is operating too close to its
maximum bump travel and handling can be negatively impacted.
5. The ratio between the front shock body motion and wheel motion is about 0.65 to 1 and the rear is 0.80
to 1. This means that the wheel travels about 1 inch for every 0.65 inches of shock body travel on the
front and 0.80 inches of spring travel on the rear. Therefore, for example, if you wanted to lower the car
½ inch from its current ride height at the right front wheel, then you would have to lower the lower spring
perch on the right front shock body by ½ x 0.65 = 0.32 inches. The rear motion ratio is calculated the
same way.
6. Repeat steps 4 & 5 for the left front, left rear and right rear wheels.
7. Armed with the data from steps 4,5 & 6, securely jack the car up and place it on four jack stands.
Remove the wheels if necessary to reach the lower spring perches. For the front dampers, loosen the
lower perch lock ring and thread the lower perch up or down by the amount you have calculated in step
5. The rear spring perch does not have a locking ring and can be turned freely. Record the location of
the perches so you can have it as a future reference if needed. Once the desired height is attained,
tighten the locking perch against the spring perch.
8. Place the wheels back on the car and lower it to the ground. Drive the car around the block or press up
and down on the car 3 or 4 times at each of the four wheels to settle the suspension before you make
any measurements. Make sure the car is in the exact same location as before and go to step 2.
Page 23 of 44

STaSIS Signature Line Maintenance Instructions
Custom Valved Ohlins Threaded Steel Dampers
The STASIS Coil Over kit is designed to provide superior service for the lifetime of your vehicle. As this
suspension system is a race car derived kit with high performance components, routine maintenance is required
to insure the optimal operation of your suspension system.
We recommend the following steps are performed bi-annually, preferably before and after the winter season.
Vehicles that are exposed to more abusive environments, such as sea salt, road salt or dirt roads may
necessitate more frequent maintenance.
1. Securely support the vehicle on four jack stands and remove the road wheels.
2. Clean the threaded portion of the damper with a non metallic brush using soap and water.
3. We recommend lowering or raising the lower spring perch to allow access to clean the
threaded portion of the damper that is covered by the perches.
4. Lubricate the threaded portion of the damper with “Boeshield T9” lubricant-protectant or a
similar wax based lubricant.
5. Return the perches to their original location and tighten the locking perches. Spray
protectant on the remaining components of the damper assembly.
6. Check the rear spherical bearings and verify that they are properly lubricated.
7. Service your dampers with STaSIS every 2 years to maintain product warranty and optimal
functionality.
8. If you have any questions about this, please call STaSIS at 707-935-9700.
Secure the road wheels and return the vehicle to the ground. Watch that the springs seat properly on the spring
perches
Page 24 of 44

A4/S4 Suspension
*When performing complete Sig.Series package, removing OEM exhaust prior to ARB
highly recommended*
Rear Anti-Roll Bar
Applications List
Qty Description Part Number
1 A4 B8 STaSIS Rear ARB 24 mm SA15.2100.00
1 S4 B8 STaSIS Rear ARB 28mm SA15.3100.00
Tools Required
Description
13mm Socket
10mm Triple Square Socket
16mm Socket
16mm Box End Wrench
Medium Prybar
Torque Values
ARB Mounting Bracket Bolts, 10mm Triple Square
Lower Drop Link Bolts
Upper Drop Link Bolts
Chassis Cross Brace Bolts
Exhaust Muffler Hanger Nuts
29 N m
54 N m
54 N m
54 N m
20 N m
Page 25 of 44

1 Before removing any parts, jack the vehicle up, and place the vehicle on four stable jack stands or use
a professional vehicle lift.
2 Support the exhaust and remove the two
exhaust muffler hanger nuts (one per
side), 13mm socket.
3 Gently pry the two center exhaust rubber
hangers of off the exhaust. Use a
lubricant (i.e. WD-40) if required.
Page 26 of 44

4 Remove the center chassis cross brace,
16mm socket.
5 Lower exhaust to give clearance for
removal and installation of the ARB.
6 Loosen but do not remove the lower ARB
drop link bolts, 16mm socket.
Page 27 of 44

7 Disconnect upper ARB drop link bolts
from the ARB and rotate link to the side,
16mm end wrenches
8 Remove the bolts attaching the ARB
brackets to the subframe (both sides),
10mm Triple Square Socket.
9 Remove the stock ARB from the car.
Gently pry off the ARB mount brackets
and rubber bushings (these will be reused
with the STaSIS ARB).
OEM ARB bushings have enough flex to
accommodate the STaSIS ARB.
Page 28 of 44

10 Install the OEM bushings and mounting
brackets with a centered distance of 26
¾” between the bolt centers of each
clamp.
11 Install STaSIS ARB into vehicle. It may be
necessary to deflect the upper control arm
by gently using a pry bar as shown to
facilitate the installation.
12 Once located, installation is the reverse of
all removal steps. Make sure to locate
drop link bolts into the ARB before
tightening the ARB Mounting Bracket
bolts. Torque all fasteners to the
specifications shown.
*NOTE*: After mounting to the vehicle,
make sure your ARB is centered between
the two clamps to avoid possible binding
and interference with suspension
components during vehicle operation.
Page 29 of 44

A4/S4 Center Differential Installation
Parts List:
Qty Description Part Number
1 High Bias Torsen DL01.0012.00
Special Tools Required
Removal
Qty Description Part Number
1 Drip Tray VAG 1306
1 Torque Wrench VAG 1331
1 Loosen quick-release fasteners - 2 and 3 - and
remove rear noise insulation.
2 Disconnect exhaust system at clamps – arrows
Disengage rear section of exhaust system at rubber
mounting and remove
Page 30 of 44

3 If installed, remove heat shield for drive shaft - arrows
4 Remove bolts – arrows – at transmission/drive shaft
flange.
Slide drive shaft together toward rear final drive. The
constant velocity joints can be moved axially.
5 Secure drive shaft to selector rod. Place drip tray VAG
G1306 under transmission.
Support transmission using engine/transmission jack
V.A.G 1383 A with transmission support T10337
attached.
6 Remove tunnel crossmember bolts - arrows -
Page 31 of 44

7 Carefully lower the transmission using
engine/transmission jack V.A.G 1383 A .
Do not lower more then, 100 mm maximum.
Remove nuts - arrow - and tunnel crossmember.
8 Place used oil collection and extraction device V.A.G
1782 under transmission.
Remove bolt - arrow - and drain transmission oil.
Install bolt - arrow - and tighten it to 40 Nm.
9 Remove bolts - A - and - arrows - and remove center
differential housing - B - carefully.
10 If gear carrier - 1 - remains in center differential housing,
proceed as follows:
Grip side ridge on gear carrier - 1 - using a pair of pliers
and remove it in direction of - arrow A - .
Using a rubber hammer , tap housing on alternating
sides - B arrows - .
CAUTION!
Do not damage sealing surfaces when doing so.
Remove center differential.
Page 32 of 44

Installation
11 Install gear carrier on transmission as follows:
Installation position: The tab on gear carrier - arrow A -
must be in opening in transmission housing - arrow B - .
12 Clean both joint surfaces in the housing.
Position center differential - 2 - over gear carrier - 1 - .
Insert plate spring - 5 - , adjustment shim(s) - 4 - and
spring - 3 - in center differential housing - 6 - .
Plate spring installation location - 5 - : The camber on
inner diameter - arrow - faces toward center differential
housing - 6 - .
Apply sealing paste AMV 188 001 02 evenly and not too
thick.
Then position center differential housing - 6 - on
transmission.
13 Press center differential housing - B - on until it makes
contact with transmission housing and hold it securely.
Install and tighten new bolts - arrows - . Tightening
specification: 7 ft-lbs plus an additional 90 degree turn.
Tighten bolts - A - Tightening specification: 18 ft-lbs.
Page 33 of 44

14 Tighten tunnel crossmember on transmission mount -
arrows - . Tightening specification: 15 ft-lbs.
15 Raise transmission and tighten the tunnel crossmember
bolts - arrows - . Tightening specification: 41 ft-lbs.
Tighten drive shaft on the transmission.
Tightening specification: 30 ft-lbs
Top off transmission oil and check oil level.
Install exhaust system and align it without tension.
16 Install drive shaft heat shield.
Tightening specification: 18 ft-lbs.
17 Reinstall rear section of exhaust system.
Page 34 of 44

A4/S4 Exhaust
Exhaust Kit Installation
Applications
Qty Description Part Number
1 A4 Sig Series Twin Tip Exhaust EX05.A4B8.00
1 S4 Sig Series Quad Tip Exhaust, Low SE221-E10-01-00
1 S4 Sig Series Quad Tip Exhaust, High SE221-E10-02-00
Instructions
1 Place vehicle in secure position. Remove factory
exhaust system up to the catalytic converter
assembly. Leave rubber hangers in position.
2 Using a 10mm socket, remove the 3 plastic nuts
holding the right side cavity cover.
*S4 Vehicle*
Steps 2-6 do not apply
3 Remove the push clip retainer in the rear right
corner of the cavity cover. Remove the cover from
the vehicle.
Page 35 of 44

4 Gently pull to remove the stock rear valence.
5 Install the supplied exhaust hanger onto the right
side muffler.
6 Install the supplied heat shield for the right side of
the vehicle using the speed nuts pictured above.
Page 36 of 44

7 Make sure there is adequate clearance between the
heat shield and the sway bar. The heat shield
should be tight against the chassis. If not, gently
bend the heat shield.
Attach new valence by gently pressing on tabs
across the bumper.
Attention: S-line vehicles must trim the new
valence to the provided template to avoid
interference during operation.
8 Install mid pipe and driver’s side muffler into
position. Slipping it into the mid-pipe and secure
loose enough for adjustment
9 Remove hardware from adjustment bracket. Be
sure to keep them for reinstallation.
10 Install passenger side into position. Slipping it into
the mid-pipe and secure loose enough for
adjustment.
11 Reinstall hardware for adjustable bracket and
tighten flanges and bracket with mufflers aligned
and spaced evenly.
Confirm the side-side distances are equal (x).
Loosen nut (arrow) on adjustable bracket and align
muffler as necessary. Torque nut to 23 Nm (17 ftlb)
12 Loosen factory hangers at rear of muffler with 13mm
wrench. Using the slots in these hangers and the
adjustable bracket, position tips in centers of
bumper cutouts.
13 Test drive and check for rattles. Re-adjust as
necessary to provide proper clearance.
Page 37 of 44

A4/S4 Brakes
Optional STaSIS Monobloc Brake Kit
Parts List:
Qty Description Part Number
1 Rotor Alcon 370X32 RH BR01.1006.00
1 Rotor Alcon 370X32 LH BR01.1007.00
4 SHCS M12x1.750x60 12.9 Blue HA01.1206.75
1 Caliper Alcon Mono6 RH Trailing BR03.1002.00
1 Caliper Alcon Mono6 LH Trailing BR03.1003.00
2 Bracket B8 14.5 Mono6 BR04.1400.00
1 Line Kit Audi Front Alcon BR20.1007.00
2 Brake Line Stop Washer BR20.1008.00
1 Project Mµ NS Pad Set BP01.6001.00
1 Fluid Motul 5.1 BP99.1000.00
Installation Guidelines
Please follow these guidelines when installing the front brake kit.
• Torque all fasteners to specification. Do not use an impact wrench.
• The rotors are side-specific, rotational direction is labeled. Open portion of crescents face toward the
direction of rotation.
• The rotors have been dynamically balanced by machining the outer edge. Flat spots along the outer
diameter are normal and will not affect the performance of the rotor.
• Tighten hydraulic connections with a line wrench.
• Bleed brakes properly to assure proper brake operation; the use of a power bleeder is
recommended.
• Ensure all ABS sensor and Pad wear sensor plugs are reconnected.
• Proper pad bedding is essential to proper brake operation.
• Initially drive the car with low braking force to check brake operation; then follow all steps listed in the
bedding process outlined at the end of this instruction manual.
• During bedding do not thermally shock the rotors with aggressive braking before the rotors have come
up to temperature. Cracks on new rotors can form due to thermal shock. Gradually increase brake
pressures as instructed in the bedding procedure.
• After bedding brakes re-torque wheel nuts to proper torque specifications.
• If vibration occurs during normal usage, check for abnormal pad wear deposits on the rotor. Double
check all fasteners and repeat the bedding process 2-3 cycles until the pad deposits on the rotor
becomes uniform.
• If the vehicle is driven in adverse weather conditions, STaSIS Engineering recommends annual
cleaning and inspection of the rotor crescents. A common source of vibration can be attributed to dirt
completely filling in the crescents on the inboard side of the rotors which in turn will not allow the pad to
function properly.
• Brake rotor wall thickness wear limit is 1.0 mm per side of rotor. Rotor face runout limit +/- 0.010 in,
when taking measurement make sure rotor is tightened down to the hub at all 5 bolt locations.
Page 38 of 44

Instructions
1 Sort the parts in the brake kit for the right and left side.
Brake bleeders face upward. Caliper mounting brackets
are universal.
Install brake pads in calipers.
Install brake lines with banjo bolt and crush washers.
Orient brake line facing straight up as shown.
2 Raise vehicle and remove the front wheels.
3 Using brake cleaner, clean the brake line connection at
the body flange. Remove all dirt and debris from this
area and from the line connection threads so that no dirt
will get into the new brake line when it is installed.
4 Remove the caliper.
Remove the ABS sensor wire from the holding bracket
on the brake caliper to facilitate removing the caliper.
Disconnect the brake pad wear sensor wire from the
driver’s side front brake inner pad.
Remove caliper mounting bolts (the bolts holding the
caliper mounting bracket to the upright). Save these
bolts as they will be reused.
Remove caliper and support it so that the brake line is
not under tension.
5 Remove the brake rotor. Clean the hub, removing all
rust from the rotor mounting surface, the rotor pilot and
wheel pilot. Apply some anti-seize to the pilot surface to
prevent rotors and wheels from sticking in the future.
Do not get any anti-seize on the rotor mounting surface
of the hub.
Page 39 of 44

6 Install caliper mounting brackets using the stock
mounting bolts and torque to 92 ft-lb. The bracket will
mount to the outside face of the upright with the angle
flange going over the mounting ears in the upright. The
OEM bolts will fit through the upright from the backside
and thread into the bracket.
7 Install the new rotors making sure they are free of dirt
and grease. Tighten the rotor retaining bolt to 48 in-lbs.
8 Place the caliper with the brake pads installed onto the
caliper mounting bracket and install the caliper mounting
bolts M12 x 1.75 x 60 and torque to 70 ft-lb. If the caliper
will not go over the rotor because the pads are too close
together, push the pads back using a pad spreader.
Note: When rotating, the rotor must always pass the
small caliper piston first. Therefore in a trailing caliper
application like we have here the small caliper piston will
be at the bottom of the caliper. The purpose is to insure
even pad wear.
Page 40 of 44

9
Replace the front brake lines.
Use an 11-mm line wrench on the hard line
nut and a 16-mm wrench on the flats on the
flex line hose-end.
Remove the stock flexible line from the hard
line and completely remove the stock caliper
and line from the vehicle.
Install the copper washer onto the new line
as shown.
Install the new flexible line, with washer using
the stock spring clip under the hard line nut
and clean with brake clean once tightened.
Install the rubber brake line grommet into the
factory bracket on the back of the upright.
Re-connect all ABS sensor wires and the
brake pad wear sensor.
10 Make sure that the brake rotor spins freely
and that the rotor is flush on the hub.
11 Bleed the brakes using fresh high-quality
brake fluid. A power bleeder is highly
recommended. Two bleeders are on each
front caliper.
Bleed the outers first until no air exits, then
the inners until no air exits
Wait 10-15 minutes.
Power bleed again while turning the ignition
on/engine off and stroke the brake pedal five
times when each bleeder is open. This
process will assure a proper bleed with the
ABS equipped system.
Tighten all bleeders securely.
12 Clean all brake line connections with brake
cleaner and compressed air so that they are
clean and dry. Start engine and pressurize
brake system several times and check for
leaks at all the brake line connections.
Correct any leaks before driving the car.
13 Check the clearance between the wheels and
the new brake calipers. Make sure that there
is at least 1/8”(0.125”) between the wheel
and the caliper.
Page 41 of 44

14 Verify that all bolts are tight and torque the
wheel lug bolts.
15 Test drive the car using the brakes gently.
16 WARNING: Do not aggressively test the
brakes until they are properly bedded.
17 Bed the pads and rotors. See the Bedding
Procedure attached to these installation
instructions. After brakes are fully bedded
recheck wheel lug bolt torque.
Page 42 of 44

STaSIS Bedding Procedure
After installing new pads, rotors, or both, it is necessary to properly bed the pad to the rotor
before using the brakes to their full capacity.
What is bedding?
Bedding is the process of depositing a layer of pad material (often called the transfer layer or
transfer film) onto the surface of the rotor. Brake rotors used on OEM style brake systems do
not require this transfer layer as the braking system is relying on friction between the pad and
the rotor material to slow the vehicle down. On STaSIS rotors, the bond between the pad
and the transfer layer is much stronger and the frictional characteristics of the pad/transfer
layer interface are far better than those of a pad/rotor interface. It is therefore crucial to bed
pads properly to ensure the reliability, performance, and longevity of your STaSIS/ALCON
brake system.
When should I bed pads and rotors?
Bedding is recommended whenever you install new pads or rotors, or experience vibrations
while braking.
• For new pads and rotors, bedding allows the manufacturing resins in the pads to burn off
slowly to avoid uneven deposits or pad glazing. Bedding also allows the rotors to relieve
any thermal stresses incurred during the manufacturing process.
• Vibrations felt through the brake pedal are most commonly a result of uneven pad
deposition, which is remedied by re-bedding the existing components.
Bedding Process
1. Upon initial installation do not bed the rotors immediately. Drive the vehicle with normal to
light braking for 1-2 days to allow the pad and rotor surfaces to conform better before bedding
in at higher temperatures.
2. Find a suitable road. You will need a relatively straight road with minimal traffic where you
can safely (and legally!) reach speeds up to 65 MPH.
3. Once the car has been driven with light braking for a few miles to bring the rotors up to the
proper operating temperature, bring the car up to approximately 65 MPH. Gently apply
constant pressure (about 10%) to the brakes, bringing the car down to about 20 MPH.
4. Accelerate briskly back to 65 MPH. Apply the brakes again, however this time use more
force (about 20%).
5. Repeat steps 2 and 3, each successive time applying more pressure. Your last two brake
applications should engage or nearly engage the ABS system.
6. Do not immediately stop the vehicle with your foot on the brakes after step 5, the
concentrated heat from the pad sitting on a non-rotating rotor will warp the rotor. Drive
vehicle using absolutely minimal brake application to cool the rotors to ambient temperature
(freeway driving).
7. Once the system has cooled, repeat the entire process.
After completing two heat cycles on the rotors, check the rotors for an even, slightly hazy
coating (often with a slight blue tint). Any spotting or blotches indicate uneven pad
deposition. Repeat the process until the rotor surface is even.
Page 43 of 44

A4/S4 Signature Series Post Installation Checklist
Suspension
o
o
o
o
o
o
Fastener clip removed from the inside fender lip on the front right and left sides.
Ensure nylock nuts are completely tightened on the front and rear upper adapter
pins. Loose nuts will cause clunking noises from the damper.
Ensure both front swaybar link bolts are reconnected to the damper fork.
Check orientation of the rear bushing spacers- shorter one against the bolt head.
Ensure all suspension and anti-roll bar mounting bolts were tightened with the
suspension compressed to the curb weight position.
Check ride height and alignment after driving the car for a few miles, as the
rubber bushings will cause the car to settle.
Brakes
o
o
o
o
o
o
o
o
Ensure all ABS sensor and Pad wear sensor plugs are reconnected
Ensure brake line grommet is properly seated on bracket. Cycle steering from full
lock left to full lock right (with the suspension compressed to the curb weight
position) and inspect for possible binding on the brake line.
After bleeding brakes, cycle pressure to the pedal and double check all bleed screws
and brake line connections for possible leakage.
Drive the car at low speeds for a few miles to check brake operation before
beginning brake bedding procedure.
During bedding do not thermally shock the rotors with aggressive braking before the
rotors have come up to temperature. Cracks on new rotors can form due to thermal
shock. Gradually increase brake pressures as instructed in the bedding procedure.
After bedding brakes re-torque wheel nuts to proper torque specifications.
After installation and bleeding is completed double check brake fluid level.
If vibration occurs during normal usage, check for abnormal pad wear deposits on
the rotor. Double check all fasteners and repeat the bedding process 2-3 cycles until
the pad deposits on the rotor becomes uniform.
Exhaust
o
o
o
o
During and after install, wipe off all assembly and shipping particles from the
exhaust. If dust is not wiped off, once the exhaust gets hot, the particles burn onto
the stainless steel finish and become permanent.
For S-line vehicles, ensure corners of the new valence are trimmed to the included
template. The exhaust will fit without trimming, but once the exhaust gets hot, it
will extend into and melt the valence.
Ensure the exhaust tips on both sides protrude from the bumper evenly and are not
touching any body panels. Clearance to all body panels should account for thermal
expansion of the exhaust, up to ½ inch in length.
Apply anti seize to all assembly bolts to allow for ease of removal.
Page 44 of 44