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Rear Brake Pad Replacement
 
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Pelican Technical Article:

Rear Brake Pad Replacement

Jared Fenton

Time:

2 hours2 hrs

Tab:

$50 to $400

Talent:

****

Tools:

Pliers, screwdrivers

Applicable Models:

Porsche 955 Cayenne (2004-10)
Porsche 955 Cayenne GTS (2008-10)
Porsche 955 Cayenne S (2003-10)
Porsche 955 Cayenne Turbo (2003-10)
Porsche 955 Cayenne Turbo S (2006-10)

Parts Required:

Rear Brake Pads, Brake Pad Wear Sensors

Hot Tip:

Apply anti-seize compound to surfaces

Performance Gain:

Better braking

Complementary Modification:

Replace brake discs

Replacing your brake pads is one of the easier jobs to perform on your Cayenne. In general, you should inspect your brake pads about every 10,000 miles and replace them if the brake lining of the pad has worn down enough to trigger the brake wear warning sensor. Once you see the brake wear warning light message in the center display screen, you should change the pads as soon as possible.

If you ignore the warning light and keep driving, the brake lining of the pad will wear away completely and the metal backing plate will start to grind into the metal face of the rotor. Using the brakes during this condition will not only give you inadequate braking, but will also begin to cut grooves in your brake discs. Once the discs are grooved, they are damaged, and there is often no way to repair them. Resurfacing will sometimes work, but often the groove cut will be deeper than is allowed by Porsche specifications. The smart thing to do is to replace your pads right away.

The procedure for replacing pads on all the wheels is basically the same. There are slight configuration differences between front and rear brakes, but in general the procedure for replacement is similar.

Locate the wheel lock key from the tool kit in your Cayenne.
Figure 1

Locate the wheel lock key from the tool kit in your Cayenne. In this photo, you can see how the splines on the key fit the splined surface of the wheel lock.

With the car still on the ground, place the wheel lock key over the lock.
Figure 2

With the car still on the ground, place the wheel lock key over the lock. Then use the lug wrench to loosen the wheel lock and the other four lug bolts. It's important that you only slightly loosen the lug bolts. Once loose, jack the car up, secure it on jack stands and remove the wheel. See our article on Jacking Up Your Cayenne for more information.

Shown here is the complete rear brake assembly on your Porsche Cayenne.
Figure 3

Shown here is the complete rear brake assembly on your Porsche Cayenne. Remove the cotter pin holding the brake pad retaining pin in place (green arrow).

Note the hole for the cotter pin in the retaining pin (green arrow).
Figure 4

Note the hole for the cotter pin in the retaining pin (green arrow). When you reinstall the pin, the hole must be facing up as shown here.

Now use a punch to gently hammer out the retaining pin (green arrow).
Figure 5

Now use a punch to gently hammer out the retaining pin (green arrow). Keep in mind that this pin also holds the brake pad retaining spring in place. You may want to hold the spring down slightly as the pin slides off of it to relieve the tension.

Now pull the brake wear sensor wiring (green arrow) out from under the clip (yellow arrow) on the pad retaining spring.
Figure 6

Now pull the brake wear sensor wiring (green arrow) out from under the clip (yellow arrow) on the pad retaining spring. Also remove the wiring from the groove cast into the caliper.

Sometimes, the old brake pads can be stuck in the caliper, preventing them from being removed.
Figure 7

Sometimes, the old brake pads can be stuck in the caliper, preventing them from being removed. In this case, you can use a screwdriver to pry the pads back. Take caution when doing so. The pads should pry back with moderate effort. Don't force them back if they are stuck. This is an indication that you may have a stuck piston in the caliper. Once the pads are free, pull them up and out of the caliper. Now look inside the caliper. You should clean this area. Make sure that the dust boots and the clamping rings inside the caliper are not ripped or damaged. If they are, then the caliper may need to be rebuilt

Now press the tab on the electrical connector (green arrow) and pull the brake wear sensor plug off.
Figure 8

Now press the tab on the electrical connector (green arrow) and pull the brake wear sensor plug off. These can sometimes be a bit tricky to release. In some cases, you may need to clean the sensor with some brake cleaner spray. At this point, you should also inspect the brake discs carefully. Using a micrometer, take a measurement of the disc thickness. If the disc is worn beyond its specifications, then it's time to replace it along with the one on the other side. See our article on Replacing Front Brake Rotors for more information.

You may find that you need to push the pistons back inside the caliper if the brake pad does not fit in.
Figure 9

You may find that you need to push the pistons back inside the caliper if the brake pad does not fit in. This is because the new pads are thicker than the old ones, and the piston is set in the old pad's position. You can do this by using a block of wood or a screwdriver as shown here. It is important that you only press on the metal portion of the piston to avoid damaging the rubber dust seals around the edge of the piston. You can also insert one of the old pads and insert a screwdriver between it and the rotor to push the pistons back in.There should be very little resistance when you push the pistons in. Do not force them. Be aware that as you push back the pistons in the calipers, you will cause the level of the brake reservoir to rise. Make sure that you don't have too much fluid in your reservoir. If the level is high, you may have to siphon out a bit from the reservoir to prevent it from overflowing. Also make sure that you have the cap securely fastened to the top of reservoir. Failure to do this may result in brake fluid accidentally getting on your paint.

Now install the new brake pads into the caliper.
Figure 10

Now install the new brake pads into the caliper. You may want to spray the back of the brake pads with some anti-squeal glue. This glue basically keeps the pads and the pistons glued together, and prevents noisy vibration. Some brands of pads may come with anti-squeal pads already attached to the rear surface. Anti-squeal pads can also be purchased separately as sheets that are peeled off and stuck on the rear of the pads.

Now take the new brake wear sensor and press the plastic tab into the tab on each brake pad (yellow arrow).
Figure 11

Now take the new brake wear sensor and press the plastic tab into the tab on each brake pad (yellow arrow). Also route the wiring for the sensor into the groove cast into the caliper (green arrow). Route the pad retaining spring underneath the red brake wear sensor wire and clip the wire into place on the spring.

Clean and lightly lubricate the brake pad retaining pin (green arrow) with high temperature grease.
Figure 12

Clean and lightly lubricate the brake pad retaining pin (green arrow) with high temperature grease. Then press it into the caliper, through the outside brake pad and over the retaining spring (yellow arrow). You may find it helps to press the spring down and you press the pin though the caliper. Keep the hole in the pin located upward.

Place the cotter pin (green arrow) through the hole in the retaining pin.
Figure 13

Place the cotter pin (green arrow) through the hole in the retaining pin. All that is left now is to re-fit the wheel. Locate the tire centering tool from the tool kit and screw it into one of the holes on the hub. This tool helps you refit the wheel onto the hub. Slide the wheel over the centering tool until it sits flush on the hub. Once in place, screw in one of the lug bolts to hold the wheel down and remove the tool. Now install all the lug bolts and torque them to 160Nm (118 ft/lbs.). When finished with both sides, press on the brake pedal repeatedly to make sure that the pads and the pistons seat properly. Also check the master cylinder brake fluid reservoir and top off the fluid if necessary. Brake pads typically take between 100 and 200 miles to completely break in. It's typical for braking performance to suffer slightly as the pads begin their wear-in period. Make sure that you avoid any heavy braking during this period.

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Comments and Suggestions:
husker76 Comments: I have a 2008 S, is it possible for me to put the token gts red calipers on or am i going to have to change out a lot more than just pads and the caliper?
December 15, 2014
  Followup from the Pelican Staff: I believe you will need a kit. You could do aftermarket calipers as well. Give our parts specialists a call at 1-888-280-7799 and they can help figure out which part or repair kit you need.
- Nick at Pelican Parts
 

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