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Rear Brake Rotor Replacement
 
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Pelican Technical Article:

Rear Brake Rotor Replacement

Jared Fenton

Time:

2 hours2 hrs

Tab:

$50 to $400

Talent:

****

Tools:

5mm, 16mm triple square driver, T50 Torx drivers, screwdrivers, rubber mallet

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:

Front Brake Rotors

Hot Tip:

Coat the hub retaining bolt with anti-seize paste

Performance Gain:

Better braking

Complementary Modification:

Replace brake pads

Brake rotors (or discs as they are often called) are perhaps the most important part of the braking system. The brake pads rub against the rotor to slow the car down. At the same time, the rotor also dissipates heat from the friction generated. If the rotor becomes too thin, or develops grooves in the surface, then their ability to stop the car decreases.

When replacing your brake pads, you should always measure the thickness of your brake rotors. If they fall below the specified value, then they should be replaced with new ones. Check for grooves in the rotor, and make sure that you take several measurements of the rotor in several different places. This will guarantee you that you get an accurate reading. If the brake rotor has a groove in it, then it should most certainly be resurfaced by a machine shop, or simply replaced with a new one. Discs with grooves not only brake less efficiently, but they also heat up to higher temperatures, and reduce your overall braking ability. Additionally, the rotors can warp from the excess heat generated.

Use a micrometer to measure the thickness of the brake disc. From the factory, the rear brake discs on your Cayenne will be 28mm. The wear limit is 27.6mm. Compared to most cars, this is a very fine tolerance and it has been my experience that most rotors end up falling below 27mm and require new discs. This is due to the weight of the vehicle and the increased heat generated by the rotors compared to those on a much lighter sports car.

If you do find that you need to replace your rotors, replacing them is a pretty simple job. The procedure for the front or the rear rotors is very similar, but for the sake of this project, we'll look at replacing the rear rotors.

The first step is to jack up the car and remove the road wheel. If you haven't already, remove the brake pads from the caliper. Refer to our article on replacing brake pads for more details. You'll now need to remove the bracket holding the hard/soft brake line and the brake wear sensor harness. This is held in place with a 10mm bolt. Slightly bend back the brake line to allow access to the caliper mounting bolts.

Now unbolt the caliper from the rear wheel hub. There are two bolts that mount the caliper to the front strut. You'll need a 16mm triple square socket to remove these bolts. Keep in mind that these bolts are torqued down to 200ft/lbs. you will likely need a breaker bar to remove them. Do not use an impact to get them loose, you risk damaging the mounting ears on the caliper. After you remove these two bolts, you should be able to move the caliper up and off the rotor. Exercise caution when moving the caliper around - make sure that you do not let the caliper hang from the rubber brake line assembly, as this can damage the line. Once the caliper is off the strut, you can set it on top of the lower rear control arm.

Now remove the T50 Torx bolt that holds on the brake rotor. Also remove the 5mm screw covering the parking brake adjuster. Rotate the smaller screw to either 9 o'clock on the right side of the car or 3 o'clock on the left side. You'll need to back off the tension on the parking brake shows slightly to remove the rotor. Place a screwdriver in the hole and move the adjuster enough to allow the rotor to come off the hub. If there is any resistance, use a rubber mallet to tap the brake disc off. Sometimes the disc will require some heavy smacks with your rubber mallet to get it off.

It's a good idea to clean the face of the wheel hub once the rotor is removed with some brake cleaner and a soft brush. Once clean, I like to put a light coat of anti-seize compound on there. It helps to prevent corrosion and also keeps the rotor from sticking to the hub.

After the new rotor is installed, replace the retaining screw with a new one (part no. N-910-282-02-M1002) and also the caliper mounting bolts (part no. N-105-556-02-M100 ) Porsche uses a coating on the threads of these bolts to secure them in place and are designed to be used only once. Torque the fasteners to spec (133 ft/lbs.) and install new brake pads. Now adjust the parking brake (see our article on parking brake adjustment). Your new rotors should last a long time, and you should see an improvement in your braking after the wear-in period for your new brake pads

Shown here is the rear brake assembly on your Porsche Cayenne.
Figure 1

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

Shown here are the two 16mm triple square bolts holding the caliper to the rear wheel hub (green arrows).
Figure 2

Shown here are the two 16mm triple square bolts holding the caliper to the rear wheel hub (green arrows). The upper bolt is partially blocked by part of the brake line. You'll need to unbolt the bracket to gain access.

Remove the 10mm bolt holding the brake line bracket to the rear caliper (green arrow).
Figure 3

Remove the 10mm bolt holding the brake line bracket to the rear caliper (green arrow).

Slightly bend the brake line slightly backwards (yellow arrow) to gain access to the upper caliper mounting bolt (green arrow).
Figure 4

Slightly bend the brake line slightly backwards (yellow arrow) to gain access to the upper caliper mounting bolt (green arrow).

You will need a 16mm triple square socket in order to remove the two caliper mounting bolts.
Figure 5

You will need a 16mm triple square socket in order to remove the two caliper mounting bolts.

Removing the upper caliper bolt will be a bit of a challenge as there isn't much access as shown here.
Figure 6

Removing the upper caliper bolt will be a bit of a challenge as there isn't much access as shown here. The caliper bolts are torqued down to 133ft/lbs from the factory. You'll want to use a large ratchet or breaker bar to loosen them up.

The lower bolt will require you to use an extension and go through the lower control arm as shown here.
Figure 7

The lower bolt will require you to use an extension and go through the lower control arm as shown here. Once the caliper is free, you can lay it on the lower control arm.

Now rotate the smaller, 5mm triple square screw (yellow arrow) until it is at either 9 o'clock (on the right side of the vehicle) or 3 o'clock (on the left side on the car).
Figure 8

Now rotate the smaller, 5mm triple square screw (yellow arrow) until it is at either 9 o'clock (on the right side of the vehicle) or 3 o'clock (on the left side on the car). Now remove the screw as well as the T50 Torx bolt holding the rotor to the hub (green arrow).

Stick a screwdriver through the 5mm hole and rotate the parking brake adjuster until you can pull the brake rotor off the hub.
Figure 9

Stick a screwdriver through the 5mm hole and rotate the parking brake adjuster until you can pull the brake rotor off the hub.

ThisPicture shows the adjuster mechanism with the rotor removed.
Figure 10

ThisPicture shows the adjuster mechanism with the rotor removed. You'll want to rotate the mechanism in the direction of the green arrow to decrease tension and in the direction of the yellow arrow to increase tension.

It is a good idea to coat the surface of the rear hub with anti-seize compound before installing the new disc.
Figure 11

It is a good idea to coat the surface of the rear hub with anti-seize compound before installing the new disc. All that's left to do now is place the new rotor on the hub, secure it, adjust the parking brake and refit the caliper.

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Comments and Suggestions:
Alberto Comments: The tightening torque of the rear caliper bolts should be 133 ftlb. not 200 that is the spec for the front.
May 19, 2016
  Followup from the Pelican Staff: Thanks for the additional info. We appreciate it. I will have the article updated.
- Nick at Pelican Parts
 
TheDudeA17 Comments: Did completed this project, thanks for the guidance, Guys! One note though: For those who are using this for any 08-10 Cayennes 957, the parking brake adjuster mechanism turns to the RIGHT instead of LEFT as the guide here suggests to decrease tension and Left to increase tension.
March 21, 2016
  Followup from the Pelican Staff: Thanks for the additional info and feedback. We appreciate it.
- Nick at Pelican Parts
 
jim Comments: Very Good Step By Step Article.. Vehichle Has Siezed rear brakes needed info to get them loose ...thks guys !!!
December 7, 2014
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 

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