Daughter's 1996 A4 quattro had worn pads, already scraping.
Installed new rotor and pads.
Today noticed rear left smoking hot.

What is typically causing stuck brake on those 1996 A4?
- piston inside caliper stuck?
- guide pins/not sliding (I cleaned and lubbed)?
- handbrake ("e-brake") cable/lever?

 

if you used to much lube on the sliding oibs that could cause it to seize since it can't fully compress.

 

Sliding "oibs"? Sliding pins maybe?

With the caliper off, should I push 'piston' out all the way and 'screw' back in to ensure it moves well?

 

im gonna say its the parking brake. not sure if the 96's are different, but the newers ones, the ebrake actually actuates the caliper itself. other vehicles of the era have a seperate drum brake inside the disc base.

ive had mine seize on me before but i never fixed it. the problem just went away.

if it isnt the ebrake, its gotta be the piston. how exaclty did you replace the pads? did you remember to turn the piston while retracting it? was there excessive rust builup?

 

i lubed and moved the e-brake since I thought it is retracting 'lazily'.
For quick test, I will unhook cable and manually push the lever back.

What is the correct way to get the e-brake moving again?

BTW: why is it called e-brake (assume emergency brake)? No one (hopefully) is using the brake in case of an emergency. I can see p brake (parking braking) or h brake (hand brake).

 

im not sure on the correct way to get it moving again but id imagine plenty of what i call squirrel **** (ie pb blaster, ect) and few hammer hits should get it moving well again.

as for it being a e brake, thats just what its called i suppose. if its the only thing i got in an emergency, well its what i'll use but techincally it is just a parking brake

 

on my year 2000, I periodically need to force the emerg brake lever at the caliper through its full range of motion while spraying with lube and even carb cleaner, to clean the road grime and grease. esp in winter/cold. I disconnect the cable at the caliper and beat it in both directions with hammer until the spring back there will force it to release-if yours is built like mine.
These old cars' parts need to be forced through their entire range of motion in many locations throughout the car when maint is done.

 

I used pliers and WD and moved the lever, but not with mucho force.
Will soak her good and use hammer for force and impact to increase motion range until it snaps back on her own.