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Car Forum / Porsche / Porshe 911 / March 2004

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Caliper Rebuild

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Parkin Hunter - 27 Mar 2004 14:24 GMT
Has anyone rebuilt their brake calipers?  Is it a reasonable project for a
shade tree mechanic?

Car is a 1980 911SC.

Thanks.

Parkin Hunter
default - 27 Mar 2004 22:17 GMT
> Has anyone rebuilt their brake calipers?  Is it a reasonable project for a
> shade tree mechanic?
[quoted text clipped - 4 lines]
>
> Parkin Hunter

Yes, it's a reasonable job for a shade tree mechanic. Did mine about 3 years
ago ('83 911SC).
I used this very good article (and dug it back up for you)
http://www.pelicanparts.com/techarticles/911_caliper_rebuild/911_caliper_rebuild.htm

I used Scotch-Brite (scouring pads) on the bores and pistons (they were
rusted) with carb cleaner until I couldn't get them any cleaner.
Had the rebuild kits already on hand (piston seal and rubber bellows).
If you get any pulsing when you stop, go ahead and replace the rotors, too.
(all 4 were only about $200 for me)
I'd go ahead and plan to replace your rubber brake lines while you are at
it. You can use either the stainless steel braided or OEM rubber lines (I
chose the OEM rubber) If you go SS, just make sure they are DOT certified
and of good quality (costs a little more)
Have about 2 qts of DOT3 brake fluid on hand and with regards to bleeding
start with the right rear, left rear, right front, left front. Best done
with 2ppl (one to press the brake, the other to tighten/loosen the bleeder)
or a pressure bleeder (about $40)
Tap the calipers after you think they're bled (air bubbles get trapped) .
You will be well rewarded for a job well done. It is amazing how much better
it stops now.
Good luck.
Parkin Hunter - 28 Mar 2004 01:32 GMT
> Yes, it's a reasonable job for a shade tree mechanic. Did mine about 3 years
> ago ('83 911SC).
>  I used this very good article (and dug it back up for you)

Thanks for the reply.  Will probably try it.  Was concerned about how much
could be done to clean the bores and the pistons.  Sounds like your use of
Scotch Brite pads did not create any problems.

Parkin Hunter
default - 28 Mar 2004 01:58 GMT
> > Yes, it's a reasonable job for a shade tree mechanic. Did mine about 3
> years
[quoted text clipped - 6 lines]
>
> Parkin Hunter

Glad to help. No problems with the Scotch Brite that I could tell.
There may be a gentler method, but the rust really required something with a
little more "bite". I was pretty vigorous with it, too.
There are no leaks after 3 yrs.
I did use a brake assembly paste to coat the pistons and bores before assy
(also on the brake pad pins and caliper bolts)
Also, one last tip: I made sure to orient the "notch" on the outside of the
piston (you'll see what I'm talking about when you take it out) at the
approximate angle relative to the caliper that is shown in the document. I
didn't make a template, but held a printout of the page up to the caliper
and adjusted it until I felt it was pretty much exact. This is apparently
done to prevent pad squeal. I must have gotten it right, since my pads don't
squeal.
I sure better when I saw the estimated cost for a dealer to rebuild them at
the bottom of the page.
Also, buying already-rebuilt calipers was prohibitively more than the cost
of the kits.
 
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