LEMON Manuals: Even more car manuals for everyone
Home >> Porsche >> 2015 >> Boxster S, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 153 (46 - Brakes - Brake Mechanics -- CARRERA (997)) >> WM 463820 Removing And Installing Rear Brake Pads (Turbo Coupe, Turbo S Coupe, Turbo S Coupe "Ed. 918 SPYDER", Turbo CABRIO, Turbo S CABRIO, Turbo S CABRIO "Ed. 918 SPYDER", Gt3, Gt3 RS, Gt3 RS 4.0) >> Installing Rear Disc Brake Pads >> Installing Rear Brake Pads - 911 Turbo

Installing Rear Brake Pads - 911 Turbo

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2013 Porsche 911, 2012 Porsche 911, 2011 Porsche 911, 2010 Porsche 911, and 2009 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.
  1. Before installing the brake pads, check the amount of wear on the brake discs. For details of minimum brake disc thickness, see → 4600TW TECHNICAL DATA/BRAKE WEAR LIMIT .
  2. Push the brake pistons back into their original position using the piston reset tool Nr.144  .
  3. Fit a new expanding spring on the brake calliper.

    Do not deform expanding spring when inserting it. Make sure that the expanding spring is positioned perfectly in the brake calliper -arrows-  .

    Fig 1: Installing Expanding Spring
    G09826093Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • Replace the brake calliper fastening screws each time the pads are changed. 
    • Brake-piston damping plates (connecting plates with vibration balancers) are used in the grey cast-iron brakes on the rear axle of the 911 Turbo (status as at July 2008). Use new brake-piston damping plates (connecting plates with vibration balancers).  
      Fig 2: Identifying Brake-Piston Damping Plate (Connecting Plate With Vibration Balancers)
      G09826094Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    • Important information for installing brake-piston damping plates (connecting plates): The connecting plates must be seated perfectly in the brake pistons and the brake pads must be positioned correctly on the guide pins (prescribed guide pin position). The connecting plates must also be bonded securely to the brake-pad backing plates. When test-driving the vehicle, do not brake too severely at the beginning to ensure subsequent/optimal driving comfort. 
      Fig 3: Installing Brake Pad
      G09826095Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Fit new brake-piston damping plates (connecting plates with vibration balancers) -3-  into the pistons. Observe the following procedure:
    1. 4.1. Cut the protective film on the connecting plates -3-  closely around the screw heads -1-  (using a suitable knife blade). As a result, the protective film can be pulled off safely (make sure there are no bits of protective film left on the bonding surface because these will prevent full-area contact).
    2. 4.2. Lightly grease surface areas of the aluminum vibration balancers -2-  on the connecting plates with brake cylinder paste before fitting.
    3. 4.3. Carefully insert connecting plates -3-  with protective film as far as they will go into the pistons without trapping the O-rings.
      Fig 4: Identifying Brake-Piston Damping Plate
      G09826096Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. 4.4. Clean the backs of the brake pads by giving them a quick wipe with a suitable solvent (to remove any dust and grease).
    5. 4.5. Pull protective film completely off the connecting plates.

      When doing this, make sure not to touch the bonding surfaces or the cleaned backs of the brake pads with your fingers.

  5. Fit brake pads.
    1. 5.1. Position brake pads before pressing them onto the bonding surface of the connecting plates. 

      First  fit the brake pads -1-  onto the guide pins and press them towards the brake disc run-off side -5-  until the brake pads are touching the guide pins (curved surface) -arrow interrupted-  .

      Then  press the brake pads -1-  straight onto the connecting plates. Do not  pretension the expanding spring -2- while doing this. This means that the pads must be positioned radially on the pins when bonding them, -arrows on side-  (with the spring force of the expanding spring -2-  ).

      1. Brake pad (position straight on the guide pin/arrows)
      2. Expanding spring
      3. Ventilation valve (top)
      4. Run-in side of brake disc (rear axle)
      5. Run-off side of brake disc (rear axle)

      Arrow  - Brake disc turning direction (forward)

      Arrow  - Required brake pad position on guide pin Broken arrow  = Position on guide pin (by pressing the pad towards the brake disc run-off side). Two arrows at the sides  = Position on guide pin (with spring force of expanding spring)

      Fig 5: Positioning Brake Pads (Rear Axle)
      G09826097Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Fit brake calliper on the wheel carrier. As a general rule, use new fastening screws -1-  .

    Observe the following procedure: 

    Screw in fastening screws -1-  (only fit loosely at first).

    Immediately after fitting the brake calliper, fit the brake pads on the brake discs. To do this, press the brake (brake pedal) with average brake pressure for approx. 5 seconds to allow the brake-piston damping plates (connecting plates) and brake pads to connect securely.

    Using slight brake pressure (approx. 10 bar/brake pedal pressed slightly), tighten the fastening screws -1- to 85 Nm (63 ftlb.).  A second fitter is required or use a brake pedal support.

    Then insert the warning contact line and warning contacts -arrows-  .

    Fig 6: Locating Warning Contact Line And Warning Contacts
    G09826098Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Check the brake fluid level and correct it if necessary. The brake fluid level must be between the MIN and MAX markings.
    Fig 7: Identifying Brake Fluid Reservoir
    G09826099Courtesy of PORSCHE CARS NORTH AMERICA, INC.
scientia non olet · About LEMON Manuals