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Brake Caliper Replacement
 
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Pelican Technical Article:

Brake Caliper Replacement

Jared Fenton

Time:

3 hours3 hrs

Tab:

$200 to $700

Talent:

***

Tools:

13mm/21mm wrenches, 16mm ZXN driver, pliers screwdrivers

Applicable Models:

Porsche 955 Cayenne (2004-08)
Porsche 955 Cayenne GTS (2008)
Porsche 955 Cayenne S (2003-08)
Porsche 955 Cayenne Turbo (2003-08)
Porsche 955 Cayenne Turbo S (2006)

Parts Required:

New brake calipers

Hot Tip:

Bleed brakes after replacing calipers

Performance Gain:

Decreased velocity with precision, consistently

Complementary Modification:

Paint brake calipers go-fast colors

The pressures and heat your brakes are subjected to can cause wear over time. One failure mode is when the piston is stuck in its bore due to rust or corrosion. This is referred to as a stuck caliper. Another failure mode is when the caliper starts to leak due to a compromised seal on the piston. It is possible to rebuild a brake caliper, however, sometimes it is better to just replace a caliper instead. I've noticed that when a caliper sticks or leaks, it has usually been damaged to the point where it isn't worth fixing.

This job requires you to jack up your Cayenne and secure it on jackstands. It also requires you remove the brake pads from the car. See our articles on Jacking up Your Cayenne and Replacing Front and Rear Brake pads for more information.

One other thing to consider is that you'll need to bleed your brakes after you have installed the new calipers. This is due to the air you introduced into the system. See our article on Bleeding Brakes for more information. Additionally, there are two methods you can use to prevent an excessive amount of brake fluid from leaking out. You can either clamp the rubber section of the brake line, or press the brake pedal down and hold it. The second method requires the use of a specialized tool, but you can easily fabricate a similar tool at home.

Front Brake Calipers: Here is the complete front brake assembly on the Porsche Cayenne.
Figure 1

Front Brake Calipers: Here is the complete front brake assembly on the Porsche Cayenne. In this article, I'll go over the steps involved with replacing the brake caliper.

Front Brake Calipers - Remove the 13mm bolt (green arrow) holding the brake pad retaining pin in place.
Figure 2

Front Brake Calipers: - Remove the 13mm bolt (green arrow) holding the brake pad retaining pin in place.

Front Brake Calipers - Use a punch to gently hammer out the retaining pin.
Figure 3

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

Front Brake Calipers - Remove the wiring for the brake wear sensor (green arrow) by pulling it out of the groove cast into the caliper.
Figure 4

Front Brake Calipers - Remove the wiring for the brake wear sensor (green arrow) by pulling it out of the groove cast into the caliper. You'll also need to pry off the brake bleeder screw dust cap, as it also holds the wiring in place (yellow arrow).

Front Brake Calipers - Press the tab on the electrical connector (green arrow) and pull the brake wear sensor plug (yellow arrow) off.
Figure 5

Front Brake Calipers - Press the tab on the electrical connector (green arrow) and pull the brake wear sensor plug (yellow arrow) 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.

Front Brake Calipers - Pull the brake wear sensor wiring (green arrow) out from under the clip (yellow arrow) on the pad retaining spring.
Figure 6

Front Brake Calipers - Pull the brake wear sensor wiring (green arrow) out from under the clip (yellow arrow) on the pad retaining spring.

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

Front Brake Calipers - 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.

Front Brake Calipers: Pull the brake pads out of the brake caliper.
Figure 8

Front Brake Calipers: Pull the brake pads out of the brake caliper.

Front Brake Calipers: Move to the inside edge of the caliper and locate the brake line connection leading into the caliper.
Figure 9

Front Brake Calipers: Move to the inside edge of the caliper and locate the brake line connection leading into the caliper. Use a 11mm flare-nut wrench to loosen the fitting enough so you can unscrew it by hand. Have a container nearby to collect the brake fluid that will come out of both the line and caliper.

Front Brake Calipers
Figure 10

Front Brake Calipers - Â"Remove the two 21mm bolts that hold the caliper to the wheel hub (green arrows). These bolts are designed for one use only and must be replaced after removal. At this point, you can remove the old caliper and install the new one. Install the new caliper in place, thread in the brake line connection and torque the new brake caliper bolts to 200ft/lbs.

Rear Brake Calipers: Here is the complete rear brake assembly on your Porsche Cayenne.
Figure 11

Rear Brake Calipers: 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).

Rear Brake Calipers: Note the hole for the cotter pin in the retaining pin (green arrow).
Figure 12

Rear Brake Calipers: 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.

Rear Brake Calipers: Use a punch to gently hammer out the retaining pin (green arrow).
Figure 13

Rear Brake Calipers: 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.

Rear Brake Calipers: Pull the brake wear sensor wiring (green arrow) out from under the clip on the pad retaining spring.
Figure 14

Rear Brake Calipers: Pull the brake wear sensor wiring (green arrow) out from under the clip on the pad retaining spring. Also remove the wiring from the groove cast into the caliper.

Rear Brake Calipers: Sometimes, the old brake pads can be stuck in the caliper, preventing them from being removed.
Figure 15

Rear Brake Calipers: 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.

Rear Brake Calipers: Press the tab on the electrical connector (green arrow) and pull the brake wear sensor plug off.
Figure 16

Rear Brake Calipers: 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.

Rear Brake Calipers: Shown here are the two 16mm ZXN bolts holding the caliper to the rear wheel hub (green arrows).
Figure 17

Rear Brake Calipers: Shown here are the two 16mm ZXN bolts holding the caliper to the rear wheel hub (green arrows). You'll also need to remove the 10mm bolt (yellow arrow) holding the brake line bracket to the caliper. Lastly, use a 11mm flare-nut wrench to loosen the brake line fitting (blue arrow) until you can thread it out by hand. Be sure to have a container nearby to collect the fluid that spills out of the caliper and brake line.

Rear Brake Calipers: You'll need a 16mm ZXN socket in order to remove the two caliper mounting bolts.
Figure 18

Rear Brake Calipers: You'll need a 16mm ZXN socket in order to remove the two caliper mounting bolts.

Rear Brake Calipers: Removing the upper caliper bolt will be a bit of a challenge as there isn't much access as shown here.
Figure 19

Rear Brake Calipers: 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 200ft/lbs from the factory. You'll want to use a large ratchet or breaker bar to loosen them up.

Rear Brake Calipers: Lastly, remove the lower 16mm ZXN bolt and lift the caliper up and off.
Figure 20

Rear Brake Calipers: Lastly, remove the lower 16mm ZXN bolt and lift the caliper up and off. When installing the new calipers, use new fastening bolts. All that's left now is to bleed the brakes.

The last step is to bleed your braking system.
Figure 21

The last step is to bleed your braking system. See our article on brake bleeding for more information. I like to use the Power Bleeder by Motive Products when I bleed brakes. It makes the job much easier than the traditional pumping method.

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Comments and Suggestions:
roby Comments: "torque the brake caliper bolts to 200ft/lbs"but 200 lbs is 22.5969658 nm is normal?thanks for your answer.
August 4, 2016
  Followup from the Pelican Staff: Porsche says front caliper to wheel carrier 200 ft-lbs, rear caliper to wheel carrier 133 ft-lbs.

Bolts and locking nuts have to be replace each time they are removed.- Nick at Pelican Parts
 

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