Installing Front Brake Pads - PCCB Brakes: Notes

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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.

Information

Make sure that the retaining pin is inserted at the correct position. The side levelling surfaces prevent the retaining pin from twisting in the brake calliper.
Do not grease the back of the disc brake pad.
The core of the warning contact wire must not be left exposed. It does not matter if the insulation is worn.
Use new mounting parts.
Remove some brake fluid from the brake fluid reservoir by suction if necessary.

Before installing the brake pads, check the amount of wear on the brake discs. → 4600TW TECHNICAL DATA/BRAKE WEAR LIMIT .
If necessary, push the brake pistons back into their original position using the brake piston resetting fixture 9472 (for 6-piston brake calliper).

Fig 1: Identifying Brake Piston Resetting Fixture
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information
- For the PCCB brake, brake pads with brake-piston damping plates (claw plates in the brake pistons) were installed on the front axle at production launch (from model year 2005).
  
  Fig 2: Identifying Claw Plates In Brake Pistons
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
- With the introduction of modified brake pads, the brake-piston damping plates (claw plates in the brake pistons) are no longer used for some derivative models and depending on the model year. Instead, the brake pad mounting plate is fitted with a damping plate -1-.
  
  Fig 3: Caution For Using Brake-Piston Damping Plates
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
- For modified brake pads with a damping plate (on the brake pad mounting plate) -1- , the damping plate -1- is covered with protective paper. Remove the protective paper completely before installing the brake pads.
  
  Fig 4: Identifying Modified Brake Pads Damping Plate
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit new disc brake pads.
1. 3.1. Pull protective paper completely off the damping plate (on the brake pad mounting plate).
2. 3.2. Fit disc brake pads.
Install expanding spring. Centre the retaining pin in the bore using the M8 auxiliary screw. To do this, push the retaining pin back with the auxiliary screw and then push the retaining pin through. Remove auxiliary screw and tighten new fastening screw at the retaining pin to 30 Nm (22 ftlb.).

Fig 5: Installing Expanding Spring
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit warning contact wire on the disc brake pads, expanding spring and brake calliper -arrows- .

Fig 6: Installing Expanding Spring And Brake Caliper Warning Contact
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Position disc brake pads by operating the brake several times.
Check the brake fluid level and correct it if necessary. The brake fluid level must be between the MIN/MAX marking.

Fig 7: Identifying Brake Fluid Reservoir
Courtesy of PORSCHE CARS NORTH AMERICA, INC.