Installing Front Disc Brake Pads

Information 

• The brake pad backing plates (rear side) must not be greased. 
• Replace vibration dampers each time the pads are changed. 
• The vibration dampers have an adhesive protective film. The protective film must be removed before installation. 
• Brake pad wear indicator: Replace warning contacts if the core of the warning contact wire is worn. Worn insulation is not important. 
• The warning contact can still be used if there are only scrape marks on the plastic part of the warning contact. 
• There are two types of warning contacts (integrated differently in the brake pad). Distinguishing feature: Wear pill (wear sensor) of warning contact is either shaped like a pin or is flat with a spring clip attachment. 

1. Check the following before installing the brake pads:
   • Check the amount of wear on the brake discs (minimum brake disc thickness). → 4600TW TECHNICAL DATA/BRAKE WEAR LIMIT .
   • The warning contacts must also be replaced in some cases (when installing a different type of brake pad for the first time). This relates to warning contacts with pin-shaped wear pills or switching to flat wear pills with a spring clip attachment for the Boxster S and Cayman S.
2. Reset the brake pistons using the piston reset tool No. 144 if necessary. Remove a little brake fluid from the reservoir by suction if necessary in order to prevent an overflow.
3. Fit new vibration dampers in the pistons. Remove protective film from the vibration dampers before installation.
   Fig 1: Identifying Vibration Damper

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   WARNING: Installation of brake pads with the wrong brake pad quality

   • Longer braking distance
   • More wear on brake pads

   → Only use the type-specific brake pads listed in the Porsche Parts Catalogue.

   → Replace the brake pads when the brake pad wear indicator light comes on, but no later than when there is a residual pad thickness of 2 mm on each axle.

   → Replace the brake discs on each axle as soon as the brake pad wear limit is reached.

4. Insert brake pads.
   WARNING: Old mounting parts fitted on the brake calliper

   • Reduced braking effect
   • Risk of damage to the brake calliper

   → Fit new expanding spring, new retaining pin and securing clip on the brake calliper.

5. Fit new expanding spring, new retaining pin and new retainer. These parts are available as a repair kit and must be replaced each time the pads are changed.
6. Insert the warning contact wire and the warning contacts.
7. Press the brake pedal several times to position the brake pads on the brake discs.
8. Check the brake fluid level and correct it if necessary. The brake fluid level must be between the MIN/MAX marking.
   Fig 2: Identifying Brake Fluid Level

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Fit the wheel. → Installing Wheel .