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Rear Brake Caliper Replacement
 
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Pelican Technical Article:

Rear Brake Caliper Replacement

Steve Vernon

Time:

2 hours2 hrs

Tab:

$NLA

Talent:

**

Tools:

19mm socket, 11mm flared nut wrench, floor jack, jack stands, wheel chocks, safety glasses, lug wrench, torque wrench

Applicable Models:

Porsche 944 Turbo (1986-89)

Parts Required:

Calipers

Hot Tip:

Don't damage the metal brake lines

Performance Gain:

Car stops better

Complementary Modification:

Replace rotor

As of the writing of this article new brake calipers form Porsche for the rear of the 944 and 951 are no longer available, so check for availability before beginning this job.

Checking your calipers should be part of your regular maintenance. Like you inspect the pads and rotors for wear and damage, you should do the same with the calipers. Some problems with calipers are hard to see with the pads in the caliper, so when you install new pads you should take the time to inspect the pistons and dust boots.

Some of the signs that a caliper is going bad are: leaking fluid, incorrect braking force, pulsing or grabbing brakes or the car pulls to one side when applying the brakes. If you are inspecting your pads and if one side of the caliper's pads is wearing down more than the other it is a sign that you have a sticking caliper and/or a faulty brake line and should inspect the brake system.

First thing you need to do is get the car up on jack stands and the rear wheels removed. Please refer to our article on jacking up your car for more information.

Note: you are going to be opening the brake hydraulic system to replace the caliper and now is a really good time to flush the system. Whether you flush the system or not, you CANNOT drive the vehicle until you have properly bled the entire brake system. Please see our article on how to bleed your Porsche brakes for additional assistance. Do NOT attempt to drive the vehicle before first properly bleeding the brakes.

To replace the caliper you will need to remove the pads, spring clip (yellow arrow) and the brake wear sensor (red arrow).
Figure 1

To replace the caliper you will need to remove the pads, spring clip (yellow arrow) and the brake wear sensor (red arrow).

You are going to have to remove the hard brake line from the rear caliper to install the new one, which means opening the brake lines or hydraulic system.
Figure 2

You are going to have to remove the hard brake line from the rear caliper to install the new one, which means opening the brake lines or hydraulic system. You should always use the proper tool when working with brake lines. On the rear caliper of the Porsche 944 it is an 11mm flared nut wrench (red arrow). The wrench will grab all sides of the nut and help prevent damage to the line (yellow arrow). Opening the line now will make pushing the pistons back into the caliper easier when you remove the brake pads.

If you are installing a new wear sensor remove the line from the caliper and the clips that hold it to the brake line (red arrow).
Figure 3

If you are installing a new wear sensor remove the line from the caliper and the clips that hold it to the brake line (red arrow).

If your sensor is not damaged you can reuse it.
Figure 4

If your sensor is not damaged you can reuse it. Should your sensor be damaged, follow the wiring until it comes to the plug located under the trailing arm and simply remove it from the mount. Unplug it and plug in the new sensor (red arrow).

You can release the spring clip from the upper mount by grabbing the center section with a set of pliers and squeezing it in and down from the top clip (red arrow).
Figure 5

You can release the spring clip from the upper mount by grabbing the center section with a set of pliers and squeezing it in and down from the top clip (red arrow). Once free of the top it will pivot down on the bottom.

Use a screwdriver between the pads and rotor and push the pistons (red arrow) back into the caliper.
Figure 6

Use a screwdriver between the pads and rotor and push the pistons (red arrow) back into the caliper. Use care around the wear sensor if you are reusing it (yellow arrow).

With the pistons back you can slide the brake pads out from the caliper.
Figure 7

With the pistons back you can slide the brake pads out from the caliper. If your wear sensor looks like this (red arrow) you need new pads and a new sensor.

Unclip the hard brake line to make installing the new caliper easier (red arrow).
Figure 8

Unclip the hard brake line to make installing the new caliper easier (red arrow).

Use a 19mm socket and remove the two retaining bolts that hold the caliper to the trailing arm (red arrows).
Figure 9

Use a 19mm socket and remove the two retaining bolts that hold the caliper to the trailing arm (red arrows). Installation is the reverse of removal. Note: you have opened the brake hydraulic system to replace the caliper. Now is a really good time to flush the system, but whether you flush the system or not you CAN NOT drive the vehicle until you have properly bled the entire brake system. Please see our article on how to bleed your Porsche brakes for additional assistance. Do NOT attempt to drive the vehicle before first properly bleeding the brakes.



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Comments and Suggestions:
DrSmith Comments: Porsche revised the rear brakes on the '86 and '87 model 944 Turbos around 1990-92. They now recommend the use of "damper plates" aka "brake pad shims" 928-352-096-10 30mm piston and 928-352-096-11 28mm piston. These shims spring fit into the caliper pistons and then an adhesive backing presses onto the cleaned brake pad backing plate. The adhesive locks the brake pad to the caliper pistons so the pad cannot slide in the caliper housing in the direction of the disk when the brakes are applied. Without these shims, the brake pads may otherwise move a few mm each time the car changes direction forward or backward and create quite a loud metallic clunk sound when the brakes are applied. Porsche did not find these unusual "one-usage" stick-on shims necessary for the front brakes. See YouTube video showing a detail of how to remove and replace the rear pads with these shims ... https://www.youtube.com/watch?v=LiF3UFF66Ys
May 23, 2016
  Followup from the Pelican Staff: Thanks for sharing your installation process and experience. These type of comments add so much to the Pelican tech community.
- Nick at Pelican Parts
 

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