were these new rotors exactly the same when laid next to the ones you took off? I am wondering if maybe the offset were different and you are having some issue with them not being seated and that caused your wheel tightening issue and may be why they won't turn after tightening the wheel?

 

Good call, RGT! Autozone gave me the wrong rotors as they have the wrong part # in their catalog. I had to order new pads and rotors from a Euro parts store. I had to put back my old rotors and new pads, but it looks like the dust shield is touching the rotor now. Any idea on how to fix this? The caliper bracket and rotor was really scuffed up bad from giving me the wrong rotor.

 

Glad you figured it out, you should be able to pry/bend the dust shield away from the rotor. So long as the caliper bracket didn't get bent when you tightened up the wheel and tried to drive you should be ok, some scrapes on the bracket shouldn't hurt it. They are pretty beefy parts but check them closely to see that they did not bend, the force of tightening the wheel against them could possibly be enough to bend things...

 

In your tool kit in the trunk is a plastic rod that screws into the hub so that the tire can be hung on the rod while you install a tire.

 

Wow. I wish I figured out what that was for a few years ago when I first got my A6 and was a complete newbie to German engineering. I spent like 25 minutes getting the rotor, hub, and wheel to line up! Of course, it takes me about 5 seconds now after lots of practice.

Great info for newer German DIY'ers.

 

It looks like I installed the rotor with the 1.75" rotor hat and the correct one for me is the 1.5" rotor hat. However when I put the 1.5" rotor hat one on, it still rubs badly. I put back the old worn rotor part back and it does not rub. it just seems that the dust shield is scraping slightly against the rotor making a little noise. Does it look like I may have to change the caliper bracket?

 

if the caliper bracket is not obviously bent and it still positions the caliper over the center of the rotor you should be fine. You may just have bent the dust shield with the wrong parts in there, if everything else looks go I would just bend the dust shield to make it clear the rotor.

 

I got my new correct rotors and pads and put them in. It is still making a rubbing sound and I looked closer and saw that the top notch of the caliper bracket is rubbing against the rotor. It does not seem obviously bent, but it must be. Remember that this all got messed up because I was given the rotor with the 1.75" rotor hat rather than the 1.5" rotor hat. How do I fix this? Just get a new bracket or is the hub and caliper also messed up?

 

I see there is a guy parting out an '01 on this forum, you might see if it has the same parts...sounds like you might have bent something unless you can bend it back and make sure you are not creating cracks you might do well to replace the caliper mounts. Maybe if you could take some good pictures someone on here might be able to tell you what is wrong?