Porsche Cayenne Brake Specs
Uploaded by
danielPorsche Cayenne Brake Specs
Uploaded by
danielService Manual: 46 - BRAKES - BRAKE MECHANICS -- 92A CAYENNE
WM 4650TW TECHNICAL DATA/BRAKE WEAR LIMITS > TECHNICAL VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
Service brake Hydraulic
(footbrake) with dual-circuit brake
grey cast iron system with
brake discs brake-circuit
(standard brake) division per axle.
with PSM Vacuum brake
(Porsche Stability booster, internally
Management) as ventilated brake
standard discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
cardiagn.com
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle.
PSM Porsche Stability
Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
Control (EDTC),
Automatic Brake
Differential
(ABD), brake
force boosting,
brake system
pre-filling.
Tandem brake 9/10 Zoll
booster Ø
(vacuum)
Boost ratio 8
Brake master 28.57 mm
cylinder Ø
Brake-circuit 24/12 mm
division
Brake disc Ø, 350 mm
front
Brake disc Ø, 330 mm
rear
Brake disc 34 mm
thickness, front
Brake disc 28 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.
Effective brake 285.2 mm
disc Ø, front
cardiagn.com
Effective brake 274.6 mm
disc Ø, rear
Piston Ø in front 6 x 36 mm
brake calliper
Piston Ø in rear 4 x 32 mm
brake calliper
Brake pad area, 448 cm2
front
Brake pad area, 200 cm2
rear
Total brake pad 648 cm2
area
Service brake Hydraulic
(footbrake) with dual-circuit brake
PCCB brake system with
discs with PSM brake-circuit
(Porsche Stability division per axle.
Management) as Vacuum brake
standard booster, internally
ventilated brake
discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle. The
brake callipers
are painted
yellow for visual
differentiation.
PSM Porsche Stability
Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
Control (EDTC),
Automatic Brake
cardiagn.com
Differential
(ABD), brake
force boosting,
brake system
pre-filling.
Tandem brake 9/10 Zoll
booster Ø
(vacuum)
Boost ratio 8/7
Brake master 28.57 mm
cylinder Ø
Brake-circuit 24/12 mm
division
Brake disc Ø, 390 mm
front
Brake disc Ø, 370 mm
rear
Brake disc 38 mm
thickness, front
Brake disc 30 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.
Effective brake 323 mm
disc Ø, front
Effective brake 314 mm
disc Ø, rear
Piston Ø in front 6 x 36 mm
brake calliper
Piston Ø in rear 4 x 32 mm
brake calliper
Brake pad area, 480 cm2
front
Brake pad area, 216 cm2
rear
Total brake pad 696 cm2
area
Pad thickness, Wear limit 2 mm approx. 9.7 mm
front
Pad thickness, Wear limit 2 mm approx. 8.8 mm
cardiagn.com
rear
Brake disc New 34 mm
thickness, front
Brake disc New 28 mm
thickness, rear
Brake disc Only as-new 33.6 mm
minimum brake discs may
thickness after be reworked!Only
machining, front rework the brake
disc
symmetrically,
evenly from both
sides!
Brake disc Only as-new 27.6 mm
minimum brake discs may
thickness after be reworked!Only
machining, rear rework the brake
disc
symmetrically,
evenly from both
sides!
Brake disc wear 32 mm
dimension, front
Brake disc wear 26 mm
dimension, rear
Peak-to-valley 0.006 mm
surface
roughness of
brake disc after
machining, max.
Thickness 0.02 mm
tolerance of
brake discs after
machining, max.
Lateral runout of 0.03 mm
brake disc, max.
Lateral runout of 0.02 mm
wheel hub, max.
Lateral runout of 0.06 mm
brake disc when
installed, max.
Pushrod play Not adjustable
Parking brake Drum brake
(foot-operated acting
parking brake) mechanically on
cardiagn.com
both rear wheels
Parking-brake Wear limit 211 210 mm
drum Ø mm
Brake shoe width 30 mm
Brake pad Wear limit 1 mm 3 mm
thickness
Pad thickness, Wear limit 2 mm approx. 8.6 mm
front
Pad thickness, Wear limit 2 mm approx. 8.9 mm
rear
Brake disc New 38 mm +0.1 mm -0.1 mm
thickness, front
Brake disc New 30 mm +0.1 mm -0.1 mm
thickness, rear
Brake disc wear Minimum brake mm(Read value
limit, front disc thickness on brake disc
(wear limit) is hub) XX.X
stamped on the
brake disc hub.
Example: Min.
Th. 37.7 mm
Brake disc wear Minimum brake mm(Read value
limit, rear disc thickness on brake disc
(wear limit) is hub) XX.X
stamped on the
brake disc hub.
Example: Min.
Th. 29.7 mm
Peak-to-valley New 0.006 mm
surface
roughness of
brake disc
Wear limit: Wear limit: Values and
Surface changes Connected procedure for:
in front and rear surface fracture > 46 51 02
brake discs 1 cm2 and/or Checking front
surface PCCB brake
roughness of discs/46 54 02
brake disc > 80 Checking rear
micrometer. PCCB brake
Replace PCCB discs.
brake discs on
both sides of the
axle.
Lateral runout of 0.03 mm
cardiagn.com
brake disc, max.
Lateral runout of 0.02 mm
wheel hub, max.
Lateral runout of 0.07 mm
brake disc when
installed, max.
Pushrod play Not adjustable
Parking brake Drum brake
(foot-operated acting
parking brake) mechanically on
both rear wheels
Parking-brake Wear limit 211 210 mm
drum Ø mm
Brake shoe width 30 mm
Brake pad Wear limit 1 mm 3 mm
thickness
WM 4650TW TECHNICAL DATA/BRAKE WEAR LIMITS > TECHNICAL VALUES >
TECHNICAL DATA - 18-INCH BRAKE SYSTEM (CAYENNE BASIC MODEL/CAYENNE
DIESEL (EXCEPT FOR USA))
Location Description Type Basic value Tolerance 1 Tolerance 2
Service brake Hydraulic
(footbrake) with dual-circuit brake
grey cast iron system with
brake discs brake-circuit
(standard brake) division per axle.
with PSM Vacuum brake
(Porsche Stability booster,
Management) as internally
standard ventilated brake
discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle.
PSM Porsche Stability
Management
(PSM) as
cardiagn.com
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
Control (EDTC),
Automatic Brake
Differential
(ABD), brake
force boosting,
brake system
pre-filling.
Tandem brake 9/10 Zoll
booster Ø
(vacuum)
Boost ratio 8
Brake master 28.57 mm
cylinder Ø
Brake-circuit 24/12 mm
division
Brake disc Ø, 350 mm
front
Brake disc Ø, 330 mm
rear
Brake disc 34 mm
thickness, front
Brake disc 28 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.
Effective brake 285.2 mm
disc Ø, front
Effective brake 274.6 mm
disc Ø, rear
Piston Ø in front 6 x 36 mm
brake calliper
Piston Ø in rear 4 x 32 mm
brake calliper
448 cm2
cardiagn.com
Brake pad area,
front
Brake pad area, 200 cm2
rear
Total brake pad 648 cm2
area
WM 4650TW TECHNICAL DATA/BRAKE WEAR LIMITS > TECHNICAL VALUES >
TECHNICAL DATA - PCCB (CAYENNE BASIC MODEL/CAYENNE S/CAYENNE
DIESEL/CAYENNE DIESEL S/CAYENNE HYBRID)
Location Description Type Basic value Tolerance 1 Tolerance 2
Service brake Hydraulic
(footbrake) with dual-circuit brake
PCCB brake system with
discs with PSM brake-circuit
(Porsche Stability division per axle.
Management) as Vacuum brake
standard booster, internally
ventilated brake
discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle. The
brake callipers
are painted
yellow for visual
differentiation.
PSM Porsche Stability
Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
Control (EDTC),
Automatic Brake
Differential
cardiagn.com
(ABD), brake
force boosting,
brake system
pre-filling.
Tandem brake 9/10 Zoll
booster Ø
(vacuum)
Boost ratio 8/7
Brake master 28.57 mm
cylinder Ø
Brake-circuit 24/12 mm
division
Brake disc Ø, 390 mm
front
Brake disc Ø, 370 mm
rear
Brake disc 38 mm
thickness, front
Brake disc 30 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.
Effective brake 323 mm
disc Ø, front
Effective brake 314 mm
disc Ø, rear
Piston Ø in front 6 x 36 mm
brake calliper
Piston Ø in rear 4 x 32 mm
brake calliper
Brake pad area, 480 cm2
front
Brake pad area, 216 cm2
rear
Total brake pad 696 cm2
area
WM 4650TW TECHNICAL DATA/BRAKE WEAR LIMITS > TECHNICAL VALUES > TEST
VALUES AND WEAR LIMITS FOR 18-INCH BRAKE SYSTEM (CAYENNE BASIC
MODEL/CAYENNE DIESEL (EXCEPT FOR USA))
cardiagn.com
Information
Depending on the extent of wear on cast iron brake discs, two condition criteria can make replacement
necessary:
Formation of cracks at advanced stage on the brake disc friction surfaces .
Minimum brake disc thickness is not retained due to wear (material erosion due to friction) . →
46500200 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) → 46530250 CHECKING
REAR BRAKE DISCS (WEAR ASSESSMENT)
Location Description Type Basic value Tolerance 1 Tolerance 2
Pad thickness, Wear limit 2 mm approx. 9.7
front mm
Pad thickness, Wear limit 2 mm approx. 8.8
rear mm
Brake disc New 34 mm
thickness, front
Brake disc New 28 mm
thickness, rear
Brake disc Only as-new 33.6 mm
minimum brake discs may
thickness after be reworked!Only
machining, front rework the brake
disc
symmetrically,
evenly from both
sides!
Brake disc Only as-new 27.6 mm
minimum brake discs may
thickness after be reworked!Only
machining, rear rework the brake
disc
symmetrically,
evenly from both
sides!
Brake disc wear 32 mm
dimension, front
Brake disc wear 26 mm
dimension, rear
Peak-to-valley 0.006 mm
surface
roughness of
brake disc after
machining, max.
cardiagn.com
Thickness 0.02 mm
tolerance of
brake discs after
machining, max.
Lateral runout of 0.03 mm
brake disc, max.
Lateral runout of 0.02 mm
wheel hub, max.
Lateral runout of 0.06 mm
brake disc when
installed, max.
Pushrod play Not adjustable
Parking brake Drum brake
(foot-operated acting
parking brake) mechanically on
both rear wheels
Parking-brake Wear limit 211 210 mm
drum Ø mm
Brake shoe width 30 mm
Brake pad Wear limit 1 mm 3 mm
thickness
Possible complaints
Damage due to lack of use (rusting). This causes vibrations in the steering wheel, noises and
brake pedal pulsation.
Brake disc becomes distorted as a result of serious driving.
Too much lateral runout when new brake discs are fitted on dirty or distorted wheel hubs.
Procedure
Check brake disc for cracks, minimum thickness, lateral runout, thickness tolerance, flatness and
surface roughness.
If necessary, (depending on the actual brake disc thickness and the brake disc wear limit) machine
the brake disc using one of the disc brake dressing machines approved by Porsche.
The brake disc must only be reworked symmetrically, i.e. evenly from both sides! Read the
operating instructions for the disc brake dressing machine!
WM 4650TW TECHNICAL DATA/BRAKE WEAR LIMITS > TECHNICAL VALUES > TEST
VALUES AND WEAR LIMITS FOR PCCB (CAYENNE BASIC MODEL/CAYENNE
S/CAYENNE DIESEL/CAYENNE DIESEL S/CAYENNE HYBRID)
Information
The following condition criteria can make replacement necessary depending on the wear of the PCCB
brake discs:
cardiagn.com
Surface changes in the brake disc friction surfaces at an advanced stage .
Minimum brake disc thickness is not retained due to wear (material erosion due to friction) .
Information
The PCCB brake disc must not be machined.
Location Description Type Basic value Tolerance 1 Tolerance 2
Pad thickness, Wear limit 2 mm approx. 8.6 mm
front
Pad thickness, Wear limit 2 mm approx. 8.9 mm
rear
Brake disc New 38 mm +0.1 mm -0.1 mm
thickness, front
Brake disc New 30 mm +0.1 mm -0.1 mm
thickness, rear
Brake disc wear Minimum brake mm (Read
limit, front disc thickness value on brake
(wear limit) is disc hub) XX.X
stamped on the
brake disc hub.
Example: Min.
Th. 37.7 mm
Brake disc wear Minimum brake mm (Read
limit, rear disc thickness value on brake
(wear limit) is disc hub) XX.X
stamped on the
brake disc hub.
Example: Min.
Th. 29.7 mm
Peak-to-valley New 0.006 mm
surface
roughness of
brake disc
Wear limit: Wear limit: Values and
Surface changes Connected procedure for:
in front and rear surface fracture 46 51 02
brake discs > 1 cm2 and/or Checking front
surface PCCB brake
roughness of discs/46 54 02
brake disc > 80 Checking rear
micrometer. PCCB brake
Replace PCCB discs.
brake discs on
both sides of the
axle.
cardiagn.com
Lateral runout of 0.03 mm
brake disc, max.
Lateral runout of 0.02 mm
wheel hub, max.
Lateral runout of 0.07 mm
brake disc when
installed, max.
Pushrod play Not adjustable
Parking brake Drum brake
(foot-operated acting
parking brake) mechanically on
both rear wheels
Parking-brake Wear limit 211 210 mm
drum Ø mm
Brake shoe width 30 mm
Brake pad Wear limit 1 mm 3 mm
thickness
Possible complaints
Too much lateral runout when new brake discs are fitted on dirty or distorted wheel hubs.
Procedure
Check brake disc for minimum thickness, lateral runout, thickness tolerance, flatness and surface
roughness.
WM 4601IN OVERVIEW OF BRAKE SYSTEMS > FRONT AXLE
Steel variant PCCB variant
Size 18"/350 mm 18"/360 mm 19"/390 mm 19"/390 mm 20"/410 mm
from 11/11
20"/420 mm
Brake calliper 6-piston 18" 6-piston 18" 6-piston 19" 6-piston 19" 6-piston 20"
wheel wheel wheel wheel wheel
Brake disc 350 mm x 34 360 mm x 36 390 mm x 38 390 mm x 38 410 mm x 38
diameter/thickness mm mm mm mm mm from
11/11420 mm x
40 mm
Cayenne X Optional
Cayenne Diesel X Optional
(except for USA)
Cayenne S X Optional
Cayenne Diesel X Optional
cardiagn.com
(USA only) and
Diesel S
Cayenne Hybrid X Optional
Cayenne GTS X Optional
Cayenne Turbo X Optional
WM 4601IN OVERVIEW OF BRAKE SYSTEMS > REAR AXLE
Steel variant PCCB variant
Size 17"/18"/330 mm 19"/358 mm 19"/20"/370 mm
Brake calliper 4-piston 17" wheel 4-piston 18" wheel 4-piston 19" wheel
Brake disc 330 mm x 28 mm 358 mm x 28 mm 370 mm x 30 mm
diameter/thickness
Cayenne X Optional
Cayenne Diesel (except X Optional
for USA)
Cayenne S X Optional
Cayenne Diesel (USA X Optional
only) and Diesel S
Cayenne Hybrid X Optional
Cayenne GTS X Optional
Cayenne Turbo X Optional
WM 4601IN OVERVIEW OF BRAKE SYSTEMS IN THE CAYENNE AS OF MODEL YEAR
2011 > FRONT AXLE
Steel Variant PCCB Variant
Size 18"/350 mm 18"/360 mm 19"/390 mm 19"/390 mm 20"/410 mm
from 11/11
20"/420 mm
Brake calliper 6-piston 18" 6-piston 18" 6-piston 19" 6-piston 19" 6-piston 20"
wheel wheel wheel wheel wheel
Brake disc 350 mm x 34 360 mm x 36 390 mm x 38 390 mm x 38 410 mm x 38
diameter/thickness mm mm mm mm mm from
11/11420 mm x
40 mm
V6 X Optional
V6 Diesel X Optional
V6 Hybrid X Optional
cardiagn.com
V8 X Optional
V8 GTS X As at 09/11 Optional
V8 Turbo X Optional
WM 4601IN OVERVIEW OF BRAKE SYSTEMS IN THE CAYENNE AS OF MODEL YEAR
2011 > REAR AXLE
Steel variant PCCB variant
Size 17"/18"/330 mm 19"/358 mm 19"/20"/370 mm
Brake calliper 4-piston 17" wheel 4-piston 18" wheel 4-piston 19" wheel
Brake disc 330 mm x 28 mm 358 mm x 28 mm 370 mm x 30 mm
diameter/thickness
V6 X Optional
V6 Diesel X Optional
V6 Hybrid X Optional
V8 X Optional
V8 GTS X As at 11/11 Optional
V8 Turbo X Optional
WM 460519 REMOVING AND INSTALLING BRAKE PEDAL > TOOLS
Designation Type Number Description
Release Tool VW Tool T10189
WM 460519 REMOVING AND INSTALLING BRAKE PEDAL > TECHNICAL VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
WM 460519 REMOVING AND INSTALLING BRAKE PEDAL > PRELIMINARY WORK >
PRELIMINARY WORK FOR REMOVING AND INSTALLING BRAKE PEDAL
cardiagn.com
1. Move the driver's seat all the way back.
2. Remove dashboard bracket. → 516819 REMOVING AND INSTALLING DASHBOARD
BRACKET
WM 460519 REMOVING AND INSTALLING BRAKE PEDAL > REMOVING BRAKE
PEDAL
Information
The pictures shown in this document may differ from the original .
Fig 1: Identifying Brake Pedal And Shaft
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Brake pedal
2. Brake pedal shaft
1. Disengage brake push rod from the brake pedal mounting using Release Tool T10189 .
Observe the following procedure for this purpose:
Fig 2: Identifying Release Tool T10189
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fig 3: Identifying Brake Pedal Release Tool
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 1.1. Release Tool T10189 -1- must be positioned in such a way that the fork is at
the correct position in the brake pedal mounting (inset shows fork engaged; view
looking away from direction of travel).
2. 1.2. Release Tool T10189 must be positioned in such a way that it is located in the
right mold of the support and is perpendicular to the vehicle floor. Deflection point of
force (bend in the release tool T10189) is right over the recess in the mounting
saddle -arrow- .
Fig 4: Levering Out Brake Pedal
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 1.3. When pressing Release Tool T10189 in direction of travel, the brake pedal
mounting is pressed apart and the ball of the push rod is released. At the same time,
pull the brake pedal away from the direction of travel and release the brake pedal
from the push rod.
Fig 5: Releasing Push Rod From Brake Pedal
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fig 6: Identifying Push Rod
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Pull out the lock -1- at the left of the brake pedal shaft -2- (-arrow- ).
Fig 7: Removing Brake Pedal Lock
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Using a hammer, press the brake pedal shaft -2- out by a few millimetres with short blows
from left to right.
4. Insert a screwdriver under the head of the brake pedal shaft -1- (right side). Carefully lever the
brake pedal shaft -1- towards the centre of the vehicle (cardan tunnel) and out of the brake
pedal -2- (-arrow- ).
Fig 8: Pressing Out Brake Pedal Shaft
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 460519 REMOVING AND INSTALLING BRAKE PEDAL > INSTALLING BRAKE
PEDAL
Information
Do not grease or spray the brake pedal shaft (bearing pin) .
Use new lock nuts .
Observe correct Tightening Torques → 4X - CHASSIS - GENERAL -- 92A CAYENNE Tightening
Torques for brake mechanism - section on "Technical values" .
Tightening Torque for brake pedal shaft (bearing pin): 20 ± 3 Nm/15 ± 2 ft. lb. .
1. Insert brake pedal into the vehicle.
2. Press the brake pedal shaft -1- fully into the brake pedal -1- (-arrow- ).
Fig 1: Pressing In Brake Pedal Shaft
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. When pushing in the brake pedal shaft -1- , make sure that the cut-out -2- on the brake pedal
shaft -1- fits into the guide -3- on the holder -4- .
Fig 2: Identifying Brake Pedal Shaft, Guide And Holder
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Slide the lock -1- at the left onto the brake pedal shaft -2- (-arrow- ).
Fig 3: Fitting Brake Pedal Lock
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Position brake pedal -1- on the push rod -2- for the brake booster.
Fig 4: Positioning Brake Pedal On Push Rod
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Press brake pedal -1- fully -arrow- until the push rod -2- engages with an audible click in the
holder -3- on the brake pedal.
Fig 5: Fitting Brake Pedal
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 460519 REMOVING AND INSTALLING BRAKE PEDAL > SUBSEQUENT WORK >
SUBSEQUENT WORK FOR REMOVING AND INSTALLING BRAKE PEDAL
1. Fit dashboard bracket. → 516819 REMOVING AND INSTALLING DASHBOARD BRACKET
WM 461019 REMOVING AND INSTALLING MOUNTING SADDLE > TECHNICAL
VALUES
Location Description Type Basic Value Tolerance 1 Tolerance 2
Screw securing Tightening 2 Nm (1.5 ft.
heat shield to Torque lb.)
left longitudinal
member
No. 1: Pedals M8 x 20 thread Tightening 23 Nm (17 ft. +/-3 Nm (+/- 2 ft.
(pedal bearing Torque lb.) lb.)
block) to
assembly plate
No. 2: Brake M8 thread Tightening 26 Nm (19 ft. +/-3 Nm (+/- 2 ft.
booster to Torque lb.) lb.)
pedals
WM 461019 REMOVING AND INSTALLING MOUNTING SADDLE > PRELIMINARY
WORK FOR REMOVING AND INSTALLING MOUNTING SADDLE
1. Remove left wheel housing liner. → 505619 REMOVING AND INSTALLING FRONT WHEEL
HOUSING LINER
2. Remove brake pedal. → 460519 REMOVING AND INSTALLING BRAKE PEDAL
3. Remove left cross panel. → 508119 REMOVING AND INSTALLING CROSS PANEL
4. Remove engine guard. → 108019 REMOVING AND INSTALLING ENGINE GUARD
5. Loosen relay carrier. → 978309 LOOSENING AND SECURING RELAY CARRIER
WM 461019 REMOVING AND INSTALLING MOUNTING SADDLE > REMOVING
MOUNTING SADDLE
cardiagn.com
Fig 1: Identifying Mounting Saddle Installation Position
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Remove relay carrier at the right -2- next to the brake pedal.
Fig 2: Removing Relay Carrier
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 1.1. Remove fastening screw -1- for the relay carrier -2- at the right next to the
brake pedal.
2. 1.2. Pull the relay carrier down and to the rear -A- and remove it from the lower
guide.
3. 1.3. Pull the upper guide -3- for the relay carrier up -B- out of the bracket -4- on the
mounting saddle.
2. Remove fastening nuts -1- for the brake booster under the dashboard.
Fig 3: Identifying Brake Booster Nuts
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Unclip cable duct cover from main wire harness against the direction of travel -arrow- and cut
the tie-wraps (three in cable duct and three on the left of the cable duct).
Fig 4: Opening Cable Duct
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Unclip fixing clips -1- for the cable duct -2- on the mounting saddle using a suitable tool, e.g.
pointed-nose pliers.
Fig 5: Identifying Clips On Cable Duct
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Unscrew the top fastening screws -1- for the mounting saddle in the plenum panel.
Fig 6: Identifying Mounting Saddle Screws (Top)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Unscrew fastening screw -1- for the mounting saddle at the bottom of the plenum panel, under
the brake booster.
Fig 7: Identifying Mounting Saddle Screw In Plenum Panel (Bottom)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Unscrew fastening screws -1- for the heat shield -2- at the left of the primary catalytic
converter on the longitudinal member.
Fig 8: Identifying Heat Shield Fastening Screws, Left
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Unscrew the bottom fastening screw -1- for the mounting saddle through the opening in the
wheel housing.
Fig 9: Identifying Mounting Saddle Screw At Bottom
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Remove mounting saddle from the vehicle.
WM 461019 REMOVING AND INSTALLING MOUNTING SADDLE > INSTALLING
MOUNTING SADDLE
1. Fit mounting saddle in the vehicle.
2. Tighten fastening screws -1- at the bottom. Tightening Torque 23 Nm (17 ft. lb.) +/-3 Nm
(+/-2 ft. lb.)
Fig 1: Identifying Screw For Mounting Saddle At Bottom
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Tighten fastening screws -1- for the heat shield -2- at the left of the longitudinal member.
Tightening Torque 2 Nm (1.5 ft. lb.)
Fig 2: Identifying Heat Shield, Left
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Tighten fastening screw -1- for the mounting saddle at the left under the brake booster.
Tightening Torque 23 Nm (17 ft. lb.) +/-3 Nm (+/-2 ft. lb.)
Fig 3: Identifying Mounting Saddle Screw In Plenum Panel At Bottom
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Tighten the top fastening screws -1- for the mounting saddle in the plenum panel. Tightening
Torque 23 Nm (17 ft. lb.) +/-3 Nm (+/-2 ft. lb.)
Fig 4: Identifying Mounting Saddle Screws At Top
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Pre-fit tie-wraps -1- in the cable duct -2- .
Fig 5: Identifying Pre-Fitting Tie-Wraps In Cable Duct
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Clip in fixing clips -1- from the cable duct -2- at the mounting saddle.
Fig 6: Identifying Cable Duct Clips
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Secure main wire harness in the cable duct and clip in cover.
Fig 7: Identifying Main Wire Harness In Cable Duct
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Secure main wire harness on the cable duct.
Fig 8: Identifying Main Wire Harness On Cable Duct
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
10. Tighten the fastening nuts -1- for the brake booster under the dashboard. Tightening Torque
26 Nm (19 ft. lb.) +/-3 Nm (+/-2 ft. lb.)
Fig 9: Identifying Brake Booster Fastening Nuts
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
11. Fit the relay carrier.
Fig 10: Fitting Relay Carrier At Right
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 11.1. Insert the guide -3- for the relay carrier at the right next to the brake pedal from
above -B- and into the holder -4- .
2. 11.2. Press the relay carrier -2- down into the guide -A- .
3. 11.3. Fit fastening screw -1- .
WM 461019 REMOVING AND INSTALLING MOUNTING SADDLE > SUBSEQUENT
WORK > SUBSEQUENT WORK FOR REMOVING AND INSTALLING MOUNTING
SADDLE
1. Install brake pedal. → 460519 REMOVING AND INSTALLING BRAKE PEDAL
2. Install left cross panel. → 508119 REMOVING AND INSTALLING CROSS PANEL
3. Secure relay carrier. → 978309 LOOSENING AND SECURING RELAY CARRIER
4. Install wheel housing liner at the left. → 505619 REMOVING AND INSTALLING FRONT
WHEEL HOUSING LINER
5. Install engine guard. → 108019 REMOVING AND INSTALLING ENGINE GUARD
WM 463402 CHECKING FRONT BRAKE PADS (PCCB) > INFORMATION >
INFORMATION ON CHECKING BRAKE PADS
Procedure During Intermediate Maintenance:
Visually inspect the brake pads for wear. There Is No Need To Remove The Wheels Unless The
Brake Fluid Needs To Be Changed At The Same Time .
Outside of brake pad: Visual inspection through the cut-outs in the rim.
Inside of brake pad: Visual inspection from below with vehicle raised.
Without an aid, the inner brake pad is not or is only partly visible on the rear axle (with the wheel fitted).
On vehicles with a stone guard on the lower wishbone, this must be removed to get a better view of the
brake pads.
A mirror can be used as an aid -arrow- .
Fig 1: Checking Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Procedure During Maintenance:
Raise the vehicle → 4X00IN LIFTING THE VEHICLE .
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Use two Assembly Pins when removing and fitting the wheel.
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
Screw the two assembly aids (Assembly Pins) -1- , instead of two wheel bolts, into the wheel hub before
removing/fitting the wheel. During removal, first remove the three remaining wheel bolts and remove the
wheel carefully without touching the brake discs.
Remove wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL .
cardiagn.com
Fig 2: Identifying Assembly Aids (Assembly Pins)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Check the brake pad thickness for wear. If in doubt following a visual inspection, you may have to
measure the thickness.
WM 463402 CHECKING FRONT BRAKE PADS (PCCB) > CHECKING > CHECKING
THICKNESS OF THE DISC BRAKE PADS
WARNING: Installation of brake pads with the wrong brake pad quality
Longer braking distance
More wear on brake pads
→ Only use the type-specific brake pads listed .
→ Replace the brake pads when the brake pad wear indicator light comes on, but no later than when
there is a residual pad thickness of 2 mm on each axle.
→ Replace the brake discs on each axle upon reaching the wear limits.
cardiagn.com
Information
If brake pad wear is indicated by the warning light, the warning contact (sender including wire and
plug connection) must also be replaced .
Replacing the warning contact can be avoided by replacing the brake pads no later than when the
pad thickness is 2.5 mm -arrows- .
Fig 1: Checking Thickness Of Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Warning contacts must be replaced if the core of the line is worn .
However, if only the plastic part of the warning contact is worn, there is no need to replace it .
Raise the vehicle → PRELIMINARY WORK - section on "Preliminary work".
Remove wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL .
Fig 2: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Visually inspect the brake pads for wear.
WM 463402 CHECKING FRONT BRAKE PADS (PCCB) > SUBSEQUENT WORK
Fit wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit wheel. → 440519 REMOVING AND INSTALLING WHEEL .
WM 463456 REPLACING FRONT BRAKE PADS (PCCB) > TOOLS
Designation Type Number Description
Piston Reset Commercially Nr. 144
Tool (replaces Available Tool
P83)
Assembly Pin VW Tool T10439 For holding the
brake calliper
WM 463456 REPLACING FRONT BRAKE PADS (PCCB) > PRELIMINARY WORK
Information
Do not open the brake system .
Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
cardiagn.com
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is
worn .
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back .
Raise the vehicle.
→ 4X00IN LIFTING THE VEHICLE .
Remove wheel. Use assembly aids (Assembly Pins) -1- .
→ 440519 REMOVING AND INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463456 REPLACING FRONT BRAKE PADS (PCCB) > REMOVING FRONT BRAKE
PADS
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
1. Expose lines.
Information
1. To gain better access for removal of the brake calliper, turn the steering fully either to the
right or left .
1. 1.1. Remove fastening screws -1, 2- for holders -3, 4- for the brake hydraulic lines.
Fig 1: Identifying Hydraulic Line Holders
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 1.2. Pull the brake pad wear indicator line out of the brake calliper.
3. 1.3. Disconnect plug connection for speed sensor.
Information
Protect the paintwork on the brake calliper from damage using a suitable cloth.
2. Carefully press the brake pads back using water pump pliers. Remove a little brake fluid from
the reservoir by suction if necessary in order to prevent an overflow!
Information
1. Do not open the brake system .
2. Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
3. The core of the warning contact wire must not be left exposed! It does not matter if the
insulation is worn .
4. If necessary, remove a little brake fluid from the reservoir by suction in order to prevent
an overflow when the disc brake pads are pushed back .
3. Partially remove brake calliper. Use removal/installation aid for brake calliper Assembly Pin
T10439 .
Fig 2: Identifying Assembly Pin For Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
1. Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier .
1. 3.1. Remove upper fastening screw on the brake calliper -arrow- and insert
Assembly Pin.
Fig 3: Inserting Upper Assembly Pin
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Remove lower fastening screw on the brake calliper -arrow- and insert
Assembly Pin.
Fig 4: Inserting Lower Assembly Pin
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 3.3. Pull the brake calliper as far as required out of installation position until the brake
calliper engages in the cut-outs on the Assembly Pins → Brake calliper tool fitted .
Carefully guide brake line and brake hose along with calliper in the process.
Fig 5: Identifying Brake Calliper Tool Fitted
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Fit the brake piston between the disc brake pads on the brake calliper using Piston Reset
Tool (Replaces P83) Nr. 144 , and press the pads back evenly → Pressing back brake pads
. Remove a little brake fluid from the reservoir by suction if necessary in order to prevent an
overflow!
Fig 6: Pressing Back Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. If You Intend To Re-Use The Brake Pads, Mark The Relevant Installation Position!
Carefully slide a commercially available screwdriver between the brake pad/brake calliper and
lever the brake pad out by turning the screwdriver slightly. When doing this, make sure not to
damage the dust boots on the brake pistons -arrows- .
Fig 7: Removing Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Remove pad retaining springs.
WM 463456 REPLACING FRONT BRAKE PADS (PCCB) > INSTALLING FRONT BRAKE
PADS
Information
Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier .
Visually inspect the thread for the brake calliper and blow it out carefully if necessary using
compressed air. Use goggles!
Replace screws .
Observe correct Tightening Torques → 4X00IN TIGHTENING TORQUES FOR THE BRAKE
HYDRAULIC SYSTEM .
WARNING: Installation of brake pads with the wrong brake pad quality
Longer braking distance
More wear on brake pads
→ Only use the type-specific brake pads listed .
→ Replace the brake pads when the brake pad wear indicator light comes on, but no later than when
there is a residual pad thickness of 2 mm on each axle.
→ Replace the brake discs on each axle as soon as the brake pad wear limit is reached.
WARNING: Old mounting parts fitted on the brake calliper
Reduced braking effect
Risk of damage to the brake calliper
→ Fit new pad retaining springs
cardiagn.com
→ Fit new fastening screws
Information
The back of the pad backing plates must not be greased .
Check disc brakes for wear. For details of wear limits see → 465102 CHECKING FRONT PCCB
BRAKE DISCS (WEAR ASSESSMENT) .
Disc brakes must be clean and free of grease .
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is
worn .
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back .
Use new repair kit .
Observe correct Tightening Torques → 4X00IN TIGHTENING TORQUES FOR THE BRAKE
HYDRAULIC SYSTEM .
Installation is performed in reverse order.
1. Fit new pad retaining springs.
2. Place disc brake pad onto the sealing surfaces of the pad retaining springs -arrows- .
Fig 1: Fitting Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Press brake pad into the brake calliper with slight pressure and slide it onto the pad retaining
pins -arrows- .
Fig 2: Pressing Brake Pad Into Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Fit disc brake pad -arrow- .
Fig 3: Fitting Disc Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463456 REPLACING FRONT BRAKE PADS (PCCB) > SUBSEQUENT WORK
1. Fit the brake calliper.
→ 473919 REMOVING AND INSTALLING FRONT BRAKE CALLIPER (PCCB)
2. Position disc brake pads by operating the brake several times.
3. Check the brake fluid level and correct it if necessary.
4. Fit wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463456 REPLACING FRONT BRAKE PADS (PCCB) > INFORMATION > BEDDING
IN THE BRAKE PADS
New brake pads require a bedding-in period of approx. 200 km (124 miles)! Only then do they achieve
their best friction and wear coefficient! During this period, the brakes should only be subjected to full
stress at high speed in emergencies!
WM 463502 CHECKING REAR BRAKE PADS (PCCB) > INFORMATION >
INFORMATION ON CHECKING BRAKE PADS
Procedure During Intermediate Maintenance:
Visually inspect the brake pads for wear. There Is No Need To Remove The Wheels Unless The
Brake Fluid Needs To Be Changed At The Same Time .
Outside of brake pad: Visual inspection through the cut-outs in the rim.
Inside of brake pad: Visual inspection from below with vehicle raised.
Without an aid, the inner brake pad is not or is only partly visible on the rear axle (with the wheel fitted).
On vehicles with a stone guard on the lower wishbone, this must be removed to get a better view of the
brake pads.
A mirror can be used as an aid -arrow- .
Fig 1: Checking Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Procedure During Maintenance:
Raise the vehicle → 4X00IN LIFTING THE VEHICLE .
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Use two Assembly Pins when removing and fitting the wheel.
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
Screw the two assembly aids (Assembly Pins) -1- , instead of two wheel bolts, into the wheel hub before
removing/fitting the wheel. During removal, first remove the three remaining wheel bolts and remove the
wheel carefully without touching the brake discs.
Remove wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL .
Fig 2: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Check the brake pad thickness for wear. If in doubt following a visual inspection, you may have to
measure the thickness.
WM 463502 CHECKING REAR BRAKE PADS (PCCB) > CHECKING > CHECKING
THICKNESS OF REAR BRAKE PADS
Procedure During Intermediate Maintenance:
Visually inspect the brake pads for wear. There Is No Need To Remove The Wheels Unless The
Brake Fluid Needs To Be Changed At The Same Time .
Outside of brake pad: Visual inspection through the cut-outs in the rim.
Inside of brake pad: Visual inspection from below with vehicle raised.
Without an aid, the inner brake pad is not or is only partly visible on the rear axle (with the wheel fitted).
On vehicles with a stone guard on the lower wishbone, this must be removed to get a better view of the
brake pads.
A mirror can be used as an aid -arrow- .
Fig 1: Checking Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Procedure During Maintenance:
Raise the vehicle → PRELIMINARY WORK - section on "Preliminary work".
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Use two Assembly Pins when removing and fitting the wheel.
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
Screw the two assembly aids (Assembly Pins) -1- , instead of two wheel bolts, into the wheel hub before
removing/fitting the wheel. During removal, first remove the three remaining wheel bolts and remove the
wheel carefully without touching the brake discs.
Remove wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL .
Fig 2: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Check the brake pad thickness for wear. If in doubt following a visual inspection, you may have to
measure the thickness.
WM 463502 CHECKING REAR BRAKE PADS (PCCB) > SUBSEQUENT WORK
Fit wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463502 CHECKING REAR BRAKE PAD (PCCB) > INFORMATION > INFORMATION
ON CHECKING BRAKE PADS
Procedure During Intermediate Maintenance:
Visually inspect the brake pads for wear. There Is No Need To Remove The Wheels Unless The
Brake Fluid Needs To Be Changed At The Same Time .
Outside of brake pad: Visual inspection through the cut-outs in the rim.
Inside of brake pad: Visual inspection from below with vehicle raised.
Without an aid, the inner brake pad is not or is only partly visible on the rear axle (with the wheel fitted).
On vehicles with a stone guard on the lower wishbone, this must be removed to get a better view of the
brake pads.
A mirror can be used as an aid -arrow- .
Fig 1: Checking Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Procedure During Maintenance:
Raise the vehicle → 4X00IN LIFTING THE VEHICLE .
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Use two Assembly Pins when removing and fitting the wheel.
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
Screw the two assembly aids (Assembly Pins) -1- , instead of two wheel bolts, into the wheel hub before
removing/fitting the wheel. During removal, first remove the three remaining wheel bolts and remove the
wheel carefully without touching the brake discs.
Remove wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL .
Fig 2: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Check the brake pad thickness for wear. If in doubt following a visual inspection, you may have to
measure the thickness.
WM 463502 CHECKING REAR BRAKE PAD (PCCB) > CHECKING > CHECKING
THICKNESS OF REAR BRAKE PADS
Procedure during intermediate maintenance:
Visually inspect the brake pads for wear. There is no need to remove the wheels unless the brake
fluid needs to be changed at the same time .
Outside of brake pad: Visual inspection through the cut-outs in the rim.
Inside of brake pad: Visual inspection from below with vehicle raised.
Without an aid, the inner brake pad is not or is only partly visible on the rear axle (with the wheel fitted).
On vehicles with a stone guard on the lower wishbone, this must be removed to get a better view of the
brake pads.
A mirror can be used as an aid -arrow- .
Fig 1: Checking Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Procedure during maintenance:
Raise the vehicle → PRELIMINARY WORK - section on "Preliminary work".
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Use two Assembly Pins when removing and fitting the wheel.
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
Screw the two assembly aids (Assembly Pins) -1- , instead of two wheel bolts, into the wheel hub before
removing/fitting the wheel. During removal, first remove the three remaining wheel bolts and remove the
wheel carefully without touching the brake discs.
Remove wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL .
Fig 2: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Check the brake pad thickness for wear. If in doubt following a visual inspection, you may have to
measure the thickness.
WM 463502 CHECKING REAR BRAKE PAD (PCCB) > SUBSEQUENT WORK
Fit wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463556 REPLACING REAR BRAKE PADS (PCCB) > INFORMATION > NOTE ON
PICTURES SHOWN
Information
The pictures shown in this document may differ from the original .
WM 463556 REPLACING REAR BRAKE PADS (PCCB) > PRELIMINARY WORK
Lift the vehicle.
→ 4X00IN LIFTING THE VEHICLE .
Remove the wheel. Use assembly aids (Assembly Pins) -1- .
→ 44051900 REMOVING AND INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
Do not open the brake system .
Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is
worn .
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back .
1. Partially remove the brake calliper.
→ 474119 REMOVING AND INSTALLING REAR BRAKE CALLIPER (PCCB)
WM 463556 REPLACING REAR BRAKE PADS (PCCB) > REMOVING REAR DISC
BRAKE PADS
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is worn!
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back.
1. Screw the two assembly aids (Assembly Pins) -1- , instead of two wheel bolts, into the wheel
hub before removing/fitting the wheel. During removal, first remove the three remaining wheel
bolts and remove the wheel carefully without touching the brake discs.
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Then (after removing the wheel), remove the two assembly aids (Assembly Pins) -1- again.
Information
Protect the paintwork on the brake calliper from damage using a suitable cloth.
3. Carefully press the brake pads back using water pump pliers.
4. Release and unclip the connector for the brake pad wear indicator and remove it from the
holder -arrow- .
Fig 2: Locating Cable Connector
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Never use an impact bolter to loosen and tighten the brake calliper on the wheel bearing
housing .
Information
1. Do not open the brake system .
2. Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
5. Get the transmission jack ready for the brake calliper and loosen the brake calliper → see Fig
3.
Fig 3: Removing Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Place the brake calliper on the transmission jack → Setting down brake calliper (shown as an
example) .
Fig 4: Setting Down Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Carefully slide a commercially available screwdriver between the brake pad/brake calliper and
lever the brake pad out by turning the screwdriver slightly. When doing this, make sure not to
damage the dust boots on the brake pistons -arrows- .
Fig 5: Removing Rear-Axle Brake Pads
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
cardiagn.com
8. Remove pad retaining springs.
WM 463556 REPLACING REAR BRAKE PADS (PCCB) > INSTALLING REAR DISC
BRAKE PADS
WARNING: Installation of brake pads with the wrong brake pad quality
Longer braking distance
More wear on brake pads
→ Only use the type-specific brake pads listed .
→ Replace the brake pads when the brake pad wear indicator light comes on, but no later than when
there is a residual pad thickness of 2 mm on each axle.
→ Replace the brake discs on each axle as soon as the brake pad wear limit is reached.
WARNING: Old mounting parts fitted on the brake calliper
Reduced braking effect
Risk of damage to the brake calliper
cardiagn.com
→ Fit new pad retaining springs
→ Fit new fastening screws
Information
The back of the pad backing plates must not be greased .
Check disc brakes for wear. For details of wear limits see → 465302 CHECKING REAR BRAKE
DISCS (WEAR ASSESSMENT) .
Disc brakes must be clean and free of grease .
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is
worn .
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back .
Use new repair kit .
Observe correct Tightening Torques → 4X00IN TIGHTENING TORQUES FOR THE BRAKE
HYDRAULIC SYSTEM .
Installation is performed in reverse order.
1. Fit new pad retaining springs.
2. Place the disc brake pad onto the sealing surfaces of the pad retaining springs.
Fig 1: Fitting Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Press the brake pad into the brake calliper with slight pressure and slide it onto the pad
retaining pins. -arrows-
Fig 2: Locating Front Axle Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Fit the disc brake pad. -direction arrow-
Fig 3: Fitting Front Axle Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Fit the brake calliper and check that the brake hose is routed correctly (do not twist the brake
hose!).
→ 474119 REMOVING AND INSTALLING REAR BRAKE CALLIPER (PCCB)
6. Position disc brake pads by operating the brake several times.
7. Check the brake fluid level and correct it if necessary.
WM 463556 REPLACING REAR BRAKE PADS (PCCB) > SUBSEQUENT WORK
1. Fit the wheel. Use assembly aids (Assembly Pins) -1- . → 44051900 REMOVING AND
INSTALLING WHEEL
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463556 REPLACING REAR BRAKE PADS (PCCB) > INFORMATION > BEDDING IN
THE BRAKE PADS
New brake pads require a bedding-in period of approx. 200 km (124 miles)! Only then do they achieve
their best friction and wear coefficient! During this period, the brakes should only be subjected to full
stress at high speed in emergencies!
WM 463602 CHECKING THICKNESS OF FRONT BRAKE PADS > INFORMATION >
INFORMATION ON CHECKING BRAKE PADS
Procedure During Intermediate Maintenance:
Visually inspect the brake pads for wear. There Is No Need To Remove The Wheels Unless The
Brake Fluid Needs To Be Changed At The Same Time .
Outside of brake pad: Visual inspection through the cut-outs in the rim.
Inside of brake pad: Visual inspection from below with vehicle raised.
Without an aid, the inner brake pad is not or is only partly visible on the rear axle (with the wheel fitted).
On vehicles with a stone guard on the lower wishbone, this must be removed to get a better view of the
brake pads.
A mirror can be used as an aid -arrow- .
Fig 1: Checking Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Procedure During Maintenance:
Raise the vehicle → 4X00IN LIFTING THE VEHICLE .
Remove wheels → 440519 REMOVING AND INSTALLING WHEEL .
Check the brake pad thickness for wear. If in doubt following a visual inspection, you may have to
measure the thickness.
WM 463602 CHECKING THICKNESS OF FRONT BRAKE PADS > CHECKING >
CHECKING THICKNESS OF BRAKE PADS
WARNING: Installation of brake pads with the wrong brake pad quality
Longer braking distance
More wear on brake pads
→ Only use the type-specific brake pads listed .
→ Replace the brake pads when the brake pad wear indicator light comes on, but no later than when
there is a residual pad thickness of 2 mm on each axle.
→ Replace the brake discs on each axle upon reaching the wear limits.
Information
If brake pad wear is indicated by the warning light, the warning contact (sender including wire and
plug connection) must also be replaced .
Replacement of the warning contact can be avoided by replacing the brake pads no later than
when the pad thickness is 2.5 mm -Arrows- .
Fig 1: Checking Thickness Of Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Warning contacts must be replaced if the core of the line is worn .
However, if only the plastic part of the warning contact is worn, there is no need to replace it .
Raise the vehicle → 4X00IN LIFTING THE VEHICLE .
Remove wheel. → 440519 REMOVING AND INSTALLING WHEEL .
1. Visually inspect the brake pads for wear.
WM 463602 CHECKING THICKNESS OF FRONT BRAKE PADS > SUBSEQUENT
WORK
Fit the wheel → 440519 REMOVING AND INSTALLING WHEEL .
WM 463619 REMOVING AND INSTALLING FRONT DISC BRAKE PADS > TOOLS
Designation Type Number Description
Piston Commercially Nr. 144
Resetting Available Tool
Fixture
(replaces P83)
cardiagn.com
Assembly Pin VW Tool T10439
WM 463619 REMOVING AND INSTALLING FRONT DISC BRAKE PADS >
INFORMATION > NOTE ON PICTURES SHOWN
Information
The pictures shown in this document may differ from the original .
WM 463619 REMOVING AND INSTALLING FRONT DISC BRAKE PADS >
PRELIMINARY WORK
Lift the vehicle.
→ 4X00IN LIFTING THE VEHICLE .
Remove the wheel. Use assembly aids (Assembly Pins) -1- .
→ 44051900 REMOVING AND INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463619 REMOVING AND INSTALLING FRONT DISC BRAKE PADS > REMOVING
FRONT DISC BRAKE PADS
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
Information
Do not open the brake system .
Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is
worn .
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back .
1. Screw the two assembly aids (Assembly Pins) -1- , instead of two wheel bolts, into the wheel
hub before removing/fitting the wheel. During removal, first remove the three remaining wheel
bolts and remove the wheel carefully without touching the brake discs.
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Then (after removing the wheel), remove the two assembly aids (Assembly Pins) -1- again.
Information
1. Do not open the brake system .
2. Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
3. The core of the warning contact wire must not be left exposed! It does not matter if the
insulation is worn .
4. If necessary, remove a little brake fluid from the reservoir by suction in order to prevent
an overflow when the disc brake pads are pushed back .
3. Partially remove the brake calliper. Check the following while doing this:
Information
1. To gain better access for removal of the brake calliper, turn the steering fully either to the
right or left .
1. 3.1. Remove the holders -1, 2- for the brake hydraulic lines from the wheel bearing
housing -3- .
Fig 2: Mounting For Hydraulic Lines
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Pull the brake pad wear indicator line out of the brake calliper.
3. 3.3. Disconnect plug connection for speed sensor.
Information
Protect the paintwork on the brake calliper from damage using a suitable cloth.
4. Carefully press the brake pads back using water pump pliers. Remove a little brake fluid from
the reservoir by suction if necessary in order to prevent an overflow!
5. Use removal/assembly aid for brake callipers Assembly Pin T10439 .
Fig 3: Identifying Assembly Pin On Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
1. Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier .
6. Remove top fastening screw on the brake calliper and insert Assembly Pin -top direction
arrow- .
Fig 4: Removing Brake Calliper Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
cardiagn.com
7. Remove bottom fastening screw on the brake calliper and insert Assembly Pin -bottom
direction arrow- .
Fig 5: Identifying Assembly Pin For Brake Calliper Fitted
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Pull the brake calliper as far as required out of installation position until the brake calliper
engages in the cut-outs on the Assembly Pins. Carefully guide the brake line and brake hose
along as well!
Fig 6: Pulling Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Fit the brake piston between the brake pads on the brake calliper using Piston Resetting
Fixture (Replaces P83) Nr. 144 and press the pads back evenly -arrows- . Remove a little
brake fluid from the reservoir by suction if necessary in order to prevent an overflow!
Fig 7: Pressing Back Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
10. If You Intend To Re-Use The Brake Pads, Mark The Relevant Installation Position .
Carefully slide a commercially available screwdriver between the brake pad/brake calliper and
lever the brake pad out by turning the screwdriver slightly. When doing this, make sure not to
damage the dust boots on the brake pistons -arrows- .
Fig 8: Removing Brake Pads With Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
11. Remove pad retaining springs.
WM 463619 REMOVING AND INSTALLING FRONT DISC BRAKE PADS > INSTALLING
FRONT DISC BRAKE PADS > INSTALLING DISC BRAKE PADS
Information
Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier .
Visually inspect the thread for the brake calliper and blow it out carefully if necessary using
compressed air. Use goggles!
Replace screws .
Observe correct Tightening Torques → 4X00IN TIGHTENING TORQUES FOR THE BRAKE
HYDRAULIC SYSTEM .
WARNING: Old mounting parts fitted on the brake calliper
Reduced braking effect
Risk of damage to the brake calliper
→ Fit new pad retaining springs
→ Fit new fastening screws
WARNING: Installation of brake pads with the wrong brake pad quality
Longer braking distance
More wear on brake pads
→ Only use the type-specific brake pads listed .
→ Replace the brake pads when the brake pad wear indicator light comes on, but no later than when
there is a residual pad thickness of 2 mm on each axle.
cardiagn.com
→ Replace the brake discs on each axle as soon as the brake pad wear limit is reached.
Installation is performed in reverse order.
1. Fit new pad retaining springs. → 465002 CHECKING FRONT BRAKE DISCS (WEAR
ASSESSMENT)
2. Place the brake pad onto the sealing surfaces of the pad retaining springs -arrows- .
Fig 1: Fitting Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Press the brake pad into the brake calliper with slight pressure and slide it onto the pad
retaining pins -arrows- .
Fig 2: Locating Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Fit the disc brake pad. -direction arrow-
Fig 3: Fitting Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463619 REMOVING AND INSTALLING FRONT DISC BRAKE PADS >
SUBSEQUENT WORK
1. Fit the brake calliper.
→ 473919 REMOVING AND INSTALLING FRONT BRAKE CALLIPER
2. Position disc brake pads by operating the brake several times.
3. Check the brake fluid level and correct it if necessary.
4. Fit the wheel. Use assembly aids (Assembly Pins) -1- . → 44051900 REMOVING AND
INSTALLING WHEEL
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463619 REMOVING AND INSTALLING FRONT DISC BRAKE PADS >
SUBSEQUENT WORK > BEDDING IN THE BRAKE PADS
New brake pads require a bedding-in period of approx. 200 km (125 miles) Only then do they achieve
their best friction and wear coefficient! During this period, the brakes should only be subjected to full
stress at high speed in emergencies!
WM 463802 CHECKING THICKNESS OF REAR BRAKE PADS > INFORMATION >
INFORMATION ON CHECKING BRAKE PADS
Procedure During Intermediate Maintenance:
Visually inspect the brake pads for wear. There Is No Need To Remove The Wheels Unless The
Brake Fluid Needs To Be Changed At The Same Time .
Outside of brake pad: Visual inspection through the cut-outs in the rim.
Inside of brake pad: Visual inspection from below with vehicle raised.
Without an aid, the inner brake pad is not or is only partly visible on the rear axle (with the wheel fitted).
On vehicles with a stone guard on the lower wishbone, this must be removed to get a better view of the
brake pads.
A mirror can be used as an aid -arrow- .
Fig 1: Checking Rear Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Procedure during maintenance:
Raise the vehicle → PRELIMINARY WORK - section on "Preliminary work".
Remove wheels → 44051900 REMOVING AND INSTALLING WHEEL .
Check the brake pad thickness for wear. If in doubt following a visual inspection, you may have to
measure the thickness.
WM 463802 CHECKING THICKNESS OF REAR BRAKE PADS > CHECKING
THICKNESS OF BRAKE PADS > CHECKING THICKNESS OF REAR BRAKE PADS
Information
If brake pad wear is indicated by the warning light, the warning contact (sender including wire and
plug connection) must also be replaced .
Replacement of the warning contact can be avoided by replacing the brake pads no later than
when the pad thickness is 2.5 mm -arrows- .
Fig 1: Checking Brake Pad Thickness
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Warning contacts must be replaced if the core of the line is worn .
However, if only the plastic part of the warning contact is worn, there is no need to replace it .
WARNING: Installation of brake pads with the wrong brake pad quality
Longer braking distance
More wear on brake pads
→ Only use the type-specific brake pads listed .
→ Replace the brake pads when the brake pad wear indicator light comes on, but no later than when
there is a residual pad thickness of 2 mm on each axle.
→ Replace the brake discs on each axle upon reaching the wear limits.
Raise the vehicle → PRELIMINARY WORK - section on "Preliminary work".
Remove wheel. → 44051900 REMOVING AND INSTALLING WHEEL .
1. Visually inspect the brake pads for wear.
cardiagn.com
WM 463802 CHECKING THICKNESS OF REAR BRAKE PADS > SUBSEQUENT WORK
Install wheel. → 44051900 REMOVING AND INSTALLING WHEEL .
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > INFORMATION >
NOTE ON PICTURES SHOWN
Information
The pictures shown in this document may differ from the original .
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > PRELIMINARY
WORK
Information
Do not open the brake system .
Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is
worn .
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back .
Lift the vehicle.
→ 4X00IN LIFTING THE VEHICLE .
Remove the wheel. Use assembly aids (Assembly Pins) -1- .
→ 44051900 REMOVING AND INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > REMOVING REAR
BRAKE PAD > REMOVING REAR DISC BRAKE PADS
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is worn!
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back.
1. Screw the two assembly aids (Assembly Pins) -1- , instead of two wheel bolts, into the wheel
hub before removing/fitting the wheel. During removal, first remove the three remaining wheel
bolts and remove the wheel carefully without touching the brake discs.
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Then (after removing the wheel), remove the two assembly aids (Assembly Pins) -1- again.
Information
Protect the paintwork on the brake calliper from damage using a suitable cloth.
3. Carefully press the brake pads back using water pump pliers.
4. Release and unclip the connector for the brake pad wear indicator and remove it from the
holder -arrow- .
Fig 2: Removing Cable
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
1. Never use an impact bolter to loosen and tighten the brake calliper on the wheel bearing
housing .
Information
1. Do not open the brake system .
2. Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
5. Get the transmission jack ready for the brake calliper and loosen the brake calliper → see Fig
3.
Fig 3: Removing Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Place the brake calliper on the transmission jack → Setting down brake calliper (shown as an
example) .
Fig 4: Setting Down Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Carefully slide a commercially available screwdriver between the brake pad/brake calliper and
lever the brake pad out by turning the screwdriver slightly. When doing this, make sure not to
damage the dust boots on the brake pistons -arrows- .
Fig 5: Removing Rear-Axle Brake Pads
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
cardiagn.com
8. Remove pad retaining springs.
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > INSTALLING >
INSTALLING REAR DISC BRAKE PADS
WARNING: Installation of brake pads with the wrong brake pad quality
Longer braking distance
More wear on brake pads
→ Only use the type-specific brake pads listed .
→ Replace the brake pads when the brake pad wear indicator light comes on, but no later than when
there is a residual pad thickness of 2 mm on each axle.
→ Replace the brake discs on each axle as soon as the brake pad wear limit is reached.
WARNING: Old mounting parts fitted on the brake calliper
Reduced braking effect
Risk of damage to the brake calliper
cardiagn.com
→ Fit new pad retaining springs
→ Fit new fastening screws
Information
The back of the pad backing plates must not be greased .
Check disc brakes for wear. For details of wear limits see → 465302 CHECKING REAR BRAKE
DISCS (WEAR ASSESSMENT) .
Disc brakes must be clean and free of grease .
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is
worn .
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back .
Use new repair kit .
Observe correct Tightening Torques → 4X00IN TIGHTENING TORQUES FOR THE BRAKE
HYDRAULIC SYSTEM .
Installation is performed in reverse order.
1. Fit new pad retaining springs.
2. Place the disc brake pad onto the sealing surfaces of the pad retaining springs.
Fig 1: Fitting Front Axle Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Press the brake pad into the brake calliper with slight pressure and slide it onto the pad
retaining pins. -arrows-
Fig 2: Locating Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Fit the brake pad. -direction arrow-
Fig 3: Fitting Front Axle Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Fit the brake calliper and check that the brake hose is routed correctly (do not twist the brake
hose!).
→ 474119 REMOVING AND INSTALLING REAR BRAKE CALLIPER
6. Position disc brake pads by operating the brake several times.
7. Check the brake fluid level and correct it if necessary.
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > SUBSEQUENT
WORK
1. Fit the wheel. Use assembly aids (Assembly Pins) -1- . → 44051900 REMOVING AND
INSTALLING WHEEL
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > INFORMATION >
BEDDING IN THE BRAKE PADS
New brake pads require a bedding-in period of approx. 200 km (125 miles) Only then do they achieve
their best friction and wear coefficient! During this period, the brakes should only be subjected to full
stress at high speed in emergencies!
WM 463656 REPLACING FRONT DISC BRAKE PADS > TOOLS
Designation Type Number Description
Piston Reset Commercially Nr. 144
Tool (replaces Available Tool
P83)
Assembly Pin VW Tool T10439 For holding the
brake calliper
cardiagn.com
WM 463656 REPLACING FRONT DISC BRAKE PADS > PRELIMINARY WORK
Information
Do not open the brake system .
Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is
worn .
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back .
Raise the vehicle.
→ 4X00IN LIFTING THE VEHICLE .
Remove wheel. Use assembly aids (Assembly Pins) -1- .
→ 440519 REMOVING AND INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463656 REPLACING FRONT DISC BRAKE PADS > REMOVING AND INSTALLING
FRONT DISC BRAKE PADS > REMOVING FRONT DISC BRAKE PADS
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
1. Expose lines.
Information
1. To gain better access for removal of the brake calliper, turn the steering fully either to the
right or left .
1. 1.1. Remove fastening screws -1, 2- for holders -3, 4- for the brake hydraulic lines.
Fig 1: Identifying Hydraulic Line Holders
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 1.2. Detach line for brake pad wear indicator from brake calliper.
3. 1.3. Disconnect plug connection for speed sensor.
Information
Protect the paintwork on the brake calliper from damage using a suitable cloth.
2. Carefully press the brake pads back using water pump pliers. Remove a little brake fluid from
the reservoir by suction if necessary in order to prevent an overflow!
Information
1. Do not open the brake system .
2. Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
3. The core of the warning contact wire must not be left exposed! It does not matter if the
insulation is worn .
4. If necessary, remove a little brake fluid from the reservoir by suction in order to prevent
an overflow when the disc brake pads are pushed back .
3. Partially remove brake calliper. Use removal/installation aid for brake calliper Assembly Pin
T10439 .
Fig 2: Identifying Assembly Pin For Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
1. Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier .
1. 3.1. Remove upper fastening screw on the brake calliper -arrow- and insert
Assembly Pin.
Fig 3: Inserting Upper Assembly Pin
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Remove lower fastening screw on the brake calliper -arrow- and insert
Assembly Pin.
Fig 4: Inserting Lower Assembly Pin
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 3.3. Pull the brake calliper as far as required out of installation position until the brake
calliper engages in the cut-outs on the Assembly Pins → Brake calliper tool fitted .
Carefully guide brake line and brake hose along with calliper in the process.
Fig 5: Pulling Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Fit the brake piston between the disc brake pads on the brake calliper using Piston Reset
Tool (Replaces P83) Nr. 144 and press the pads back evenly → Pressing back brake pads .
Remove a little brake fluid from the reservoir by suction if necessary in order to prevent an
overflow!
Fig 6: Pressing Back Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. If you intend to re-use the brake pads, mark the relevant installation position! Carefully
slide a commercially available screwdriver between the brake pad/brake calliper and lever the
brake pad out by turning the screwdriver slightly. When doing this, make sure not to damage
the dust boots on the brake pistons -arrows- .
Fig 7: Removing Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Remove pad retaining springs.
WM 463656 REPLACING FRONT DISC BRAKE PADS > REMOVING AND INSTALLING
FRONT DISC BRAKE PADS > INSTALLING FRONT DISC BRAKE PADS
Information
Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier .
Visually inspect the thread for the brake calliper and blow it out carefully if necessary using
compressed air. Use goggles!
Replace screws .
Observe correct Tightening Torques → 4X00IN TIGHTENING TORQUES FOR THE BRAKE
HYDRAULIC SYSTEM .
WARNING: Installation of brake pads with the wrong brake pad quality
Longer braking distance
More wear on brake pads
→ Only use the type-specific brake pads listed .
→ Replace the brake pads when the brake pad wear indicator light comes on, but no later than when
there is a residual pad thickness of 2 mm on each axle.
→ Replace the brake discs on each axle as soon as the brake pad wear limit is reached.
WARNING: Old mounting parts fitted on the brake calliper
Reduced braking effect
Risk of damage to the brake calliper
→ Fit new pad retaining springs
cardiagn.com
→ Fit new fastening screws
Information
The back of the pad backing plates must not be greased .
Check disc brakes for wear. For details of wear limits, see → 465002 CHECKING FRONT BRAKE
DISCS (WEAR ASSESSMENT) .
Disc brakes must be clean and free of grease .
The core of the warning contact wire must not be left exposed! Worn insulation is not important .
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back .
Use a new repair kit .
Observe correct Tightening Torques → 4X00IN TIGHTENING TORQUES FOR THE BRAKE
HYDRAULIC SYSTEM .
Installation is performed in reverse order.
1. Fit new pad retaining springs.
2. Place disc brake pad onto the sealing surfaces of the pad retaining springs -arrows- .
Fig 1: Fitting Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Press brake pad into the brake calliper with slight pressure and slide it onto the pad retaining
pins -arrows- .
Fig 2: Pressing Brake Pad Into Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Fit disc brake pad -arrow- .
Fig 3: Fitting Disc Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463656 REPLACING FRONT DISC BRAKE PADS > SUBSEQUENT WORK
1. Fit brake calliper. → 473919 REMOVING AND INSTALLING FRONT BRAKE CALLIPER
2. Position disc brake pads by operating the brake several times.
3. Check the brake fluid level and correct it if necessary.
4. Fit wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463656 REPLACING FRONT DISC BRAKE PADS > INFORMATION > BEDDING IN
THE BRAKE PADS
New brake pads require a bedding-in period of approx. 200 km (124 miles)! Only then do they achieve
their best friction and wear coefficient! During this period, the brakes should only be subjected to full
stress at high speed in emergencies!
WM 463802 CHECKING THICKNESS OF REAR BRAKE PADS > INFORMATION >
INFORMATION ON CHECKING BRAKE PADS
Procedure During Intermediate Maintenance:
Visually inspect the brake pads for wear. There Is No Need To Remove The Wheels Unless The
Brake Fluid Needs To Be Changed At The Same Time .
Outside of brake pad: Visual inspection through the cut-outs in the rim.
Inside of brake pad: Visual inspection from below with vehicle raised.
Without an aid, the inner brake pad is not or is only partly visible on the rear axle (with the wheel fitted).
On vehicles with a stone guard on the lower wishbone, this must be removed to get a better view of the
brake pads.
A mirror can be used as an aid -arrow- .
Fig 1: Checking Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Procedure During Maintenance:
Raise the vehicle → 4X00IN LIFTING THE VEHICLE .
Remove wheels → REMOVING WHEEL - section on "Removing".
Check the brake pad thickness for wear. If in doubt following a visual inspection, you may have to
measure the thickness.
WM 463802 CHECKING THICKNESS OF REAR BRAKE PADS > CHECKING
THICKNESS OF BRAKE PADS > CHECKING THICKNESS OF REAR BRAKE PADS
WARNING: Installation of brake pads with the wrong brake pad quality
Longer braking distance
More wear on brake pads
→ Only use the type-specific brake pads listed .
→ Replace the brake pads when the brake pad wear indicator light comes on, but no later than when
there is a residual pad thickness of 2 mm on each axle.
→ Replace the brake discs on each axle upon reaching the wear limits.
Information
If brake pad wear is indicated by the warning light, the warning contact (sender including wire and
plug connection) must also be replaced .
Replacement of the warning contact can be avoided by replacing the brake pads no later than
when the pad thickness is 2.5 mm -Arrows- .
Fig 1: Checking Thickness Of Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Warning contacts must be replaced if the core of the line is worn .
However, if only the plastic part of the warning contact is worn, there is no need to replace it .
1. Visually inspect the brake pads for wear.
WM 463802 CHECKING THICKNESS OF REAR BRAKE PADS > SUBSEQUENT WORK
Fit the wheel → INSTALLING WHEEL - section on "Installing".
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > INFORMATION >
NOTE ON PICTURES SHOWN
Information
The pictures shown in this document may differ from the original .
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > PRELIMINARY
WORK
Information
Do not open the brake system .
cardiagn.com
Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is
worn .
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back .
Lift the vehicle.
→ 4X00IN LIFTING THE VEHICLE .
Remove the wheel. Use assembly aids (Assembly Pins) -1- .
→ 44051900 REMOVING AND INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > REMOVING REAR
BRAKE PAD > REMOVING REAR DISC BRAKE PADS
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is worn!
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back.
1. Screw the two assembly aids (Assembly Pins) -1- , instead of two wheel bolts, into the wheel
hub before removing/fitting the wheel. During removal, first remove the three remaining wheel
bolts and remove the wheel carefully without touching the brake discs.
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Then (after removing the wheel), remove the two assembly aids (Assembly Pins) -1- again.
Information
Protect the paintwork on the brake calliper from damage using a suitable cloth.
3. Carefully press the brake pads back using water pump pliers.
4. Release and unclip the connector for the brake pad wear indicator and remove it from the
holder -arrow- .
Fig 2: Removing Cable
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
1. Never use an impact bolter to loosen and tighten the brake calliper on the wheel bearing
housing .
Information
1. Do not open the brake system .
2. Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
5. Get the transmission jack ready for the brake calliper and loosen the brake calliper → see Fig
3.
Fig 3: Removing Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Place the brake calliper on the transmission jack → Setting down brake calliper (shown as an
example) .
Fig 4: Setting Down Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Carefully slide a commercially available screwdriver between the brake pad/brake calliper and
lever the brake pad out by turning the screwdriver slightly. When doing this, make sure not to
damage the dust boots on the brake pistons -arrows- .
Fig 5: Removing Rear-Axle Brake Pads
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
cardiagn.com
8. Remove pad retaining springs.
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > INSTALLING >
INSTALLING REAR DISC BRAKE PADS
WARNING: Installation of brake pads with the wrong brake pad quality
Longer braking distance
More wear on brake pads
→ Only use the type-specific brake pads listed .
→ Replace the brake pads when the brake pad wear indicator light comes on, but no later than when
there is a residual pad thickness of 2 mm on each axle.
→ Replace the brake discs on each axle as soon as the brake pad wear limit is reached.
WARNING: Old mounting parts fitted on the brake calliper
Reduced braking effect
Risk of damage to the brake calliper
cardiagn.com
→ Fit new pad retaining springs
→ Fit new fastening screws
Information
The back of the pad backing plates must not be greased .
Check disc brakes for wear. For details of wear limits see → 465302 CHECKING REAR BRAKE
DISCS (WEAR ASSESSMENT) .
Disc brakes must be clean and free of grease .
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is
worn .
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back .
Use new repair kit .
Observe correct Tightening Torques → 4X00IN TIGHTENING TORQUES FOR THE BRAKE
HYDRAULIC SYSTEM .
Installation is performed in reverse order.
1. Fit new pad retaining springs.
2. Place the disc brake pad onto the sealing surfaces of the pad retaining springs.
Fig 1: Locating Front Axle Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Press the brake pad into the brake calliper with slight pressure and slide it onto the pad
retaining pins. -arrows-
Fig 2: Pressing Brake Pad Into Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Fit the brake pad. -direction arrow-
Fig 3: Fitting Front Axle Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Fit the brake calliper and check that the brake hose is routed correctly (do not twist the brake
hose!).
→ 474119 REMOVING AND INSTALLING REAR BRAKE CALLIPER
6. Position disc brake pads by operating the brake several times.
7. Check the brake fluid level and correct it if necessary.
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > SUBSEQUENT
WORK
1. Fit the wheel. Use assembly aids (Assembly Pins) -1- . → 44051900 REMOVING AND
INSTALLING WHEEL
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > INFORMATION >
BEDDING IN THE BRAKE PADS
New brake pads require a bedding-in period of approx. 200 km (125 miles) Only then do they achieve
their best friction and wear coefficient! During this period, the brakes should only be subjected to full
stress at high speed in emergencies!
WM 463856 REPLACING REAR DISC BRAKE PADS > PRELIMINARY WORK
Raise the vehicle.
→ 4X00IN LIFTING THE VEHICLE .
Remove wheel. Use assembly aids (Assembly Pins) -1- .
→ 440519 REMOVING AND INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
Do not open the brake system .
Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is
worn .
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back .
1. Partially remove brake calliper.
→ 474119 REMOVING AND INSTALLING REAR BRAKE CALLIPER
WM 463856 REPLACING REAR DISC BRAKE PADS > REMOVING AND INSTALLING
REAR DISC BRAKE PADS > REMOVING REAR DISC BRAKE PADS
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
The core of the warning contact wire must not be left exposed! Worn insulation is not important!
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back!
Information
Protect the paintwork on the brake calliper from damage using a suitable cloth.
1. Carefully press the brake pads back using water pump pliers.
2. Release and unclip connector for the brake pad wear indicator and remove it from the holder
cardiagn.com
-arrow- .
Fig 1: Removing Cable
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
1. Never use an impact bolter to loosen and tighten the brake calliper on the wheel bearing
housing .
Information
1. Do not open the brake system .
2. Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
3. Get the transmission jack ready for the brake calliper and loosen the brake calliper -arrows- .
Fig 2: Removing Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Place the brake calliper on the transmission jack.
5. Carefully slide a commercially available screwdriver between the brake pad/brake calliper and
lever the brake pad out by turning the screwdriver slightly. When doing this, make sure not to
damage the dust boots on the brake pistons -arrow- .
Fig 3: Removing Brake Pads
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Remove pad retaining springs.
WM 463856 REPLACING REAR DISC BRAKE PADS > REMOVING AND INSTALLING
REAR DISC BRAKE PADS > INSTALLING REAR DISC BRAKE PADS
WARNING: Installation of brake pads with the wrong brake pad quality
Longer braking distance
More wear on brake pads
→ Only use the type-specific brake pads listed .
→ Replace the brake pads when the brake pad wear indicator light comes on, but no later than when
there is a residual pad thickness of 2 mm on each axle.
→ Replace the brake discs on each axle as soon as the brake pad wear limit is reached.
WARNING: Old mounting parts fitted on the brake calliper
Reduced braking effect
Risk of damage to the brake calliper
→ Fit new pad retaining springs
→ Fit new fastening screws
Information
The back of the pad backing plates must not be greased .
Check disc brakes for wear. For details of wear limits see → 465302 CHECKING REAR BRAKE
DISCS (WEAR ASSESSMENT) .
Disc brakes must be clean and free of grease .
cardiagn.com
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is
worn .
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back .
Use new repair kit .
Observe correct Tightening Torques → 4X00IN TIGHTENING TORQUES FOR THE BRAKE
HYDRAULIC SYSTEM .
Installation is performed in reverse order.
1. Fit new pad retaining springs.
2. Place disc brake pad on the sealing surfaces of the pad retaining springs -arrows- .
Fig 1: Fitting Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Press brake pad into the brake calliper with slight pressure and slide it onto the pad retaining
pins -arrows- .
Fig 2: Pressing Brake Pad Into Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Fit disc brake pad -arrow- .
Fig 3: Fitting Disc Brake Pad
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Fit the brake calliper and check that the brake hose is routed correctly (do not twist the brake
hose!).
→ 474119 REMOVING AND INSTALLING REAR BRAKE CALLIPER
6. Position disc brake pads by operating the brake several times.
7. Check the brake fluid level and correct it if necessary.
WM 463856 REPLACING REAR DISC BRAKE PADS > SUBSEQUENT WORK
1. Fit wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 463856 REPLACING REAR DISC BRAKE PADS > INFORMATION > BEDDING IN
THE BRAKE PADS
New brake pads require a bedding-in period of approx. 200 km (124 miles)! Only then do they achieve
their best friction and wear coefficient! During this period, the brakes should only be subjected to full
stress at high speed in emergencies!
WM 465002 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) > TOOLS
Designation Type Number Description
Adapter Plate Special Tool 9510/1
Dial Gauge Set Commercially Nr. 147-1
With Ball Joint Available Tool
Arm
cardiagn.com
WM 465002 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) > TECHNICAL
VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
Brake Discs Maximum Crack 0.5 x a mm
Length
Brake Discs Maximum Crack 1 mm
Width
Brake Discs Maximum Crack 1.5 mm
Depth
WM 465002 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) >
INFORMATION
Information
The pictures shown in this document may differ from the original .
WM 465002 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) >
INFORMATION > INFORMATION ON WEAR ASSESSMENT
Normally, brake disc replacement is necessary after the thickness falls below the minimum. In rare,
isolated cases (of very high loads for long periods) replacement may be necessary due to crack
formation. To a certain extent these cracks may be rated as not important. A description is given in the
following sections of when to replace brake discs.
Cracks occur as a result of material fatigue due to frequent and extreme thermal expansion fluctuations.
Particularly in cases of very high loads for long periods, these thermal expansion fluctuations produce
internal stresses. The result may be cracks in the friction surface. These cracks allow relaxation of the
friction disc, so that the speed at which the cracks develop is very slow.
Cracks run from the centre of the friction surface to the (inner and outer) edges of the brake disc. As
different vehicle types have different brake disc sizes, differences arise for the maximum crack length
limits.
Maximum crack length limit is calculated as follows:
0.5 x a (-a- = width of friction surface in mm).
Fig 1: Identifying Brake Disc Friction Surface Width
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Larger cracks impair braking comfort and reduce brake disc strength, therefore making brake disc
replacement necessary as a precaution.
Irrespective of the crack length, the brake disc must be replaced if the crack has extended as far as the
outer and/or inner edge of the disc.
WM 465002 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) >
INFORMATION > BEDDING IN THE BRAKE PADS AND BRAKE DISCS
New brake pads require a bedding-in period of approx. 200 km (124 miles)! Only then do they achieve
their best friction and wear coefficient. During this period, the brakes should be subjected to full stress
when travelling at high speed only in emergencies. The slightly reduced braking effect must be
compensated for by increased pressure on the brake pedal. The same also applies after replacing or
machining brake discs.
WM 465002 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) > CHECKING >
CHECKING FRONT BRAKE DISCS - EVALUATING CRACKS
Different vehicle types have different brake disc sizes. This produces differences for the maximum crack
length limits.
Maximum crack length limit is calculated as follows:
0.5 x a (-a- = width of friction surface in mm).
Fig 1: Identifying Brake Disc Friction Surface Width
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
The length of a crack can be measured with a steel rule, for example. → Brake discs
Fig 2: Checking Brake Disc Cracks
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
Irrespective of the crack length, the brake disc must be replaced if the crack has extended as far as the
outer and/or inner edge of the disc.
As a precaution, brake discs must be replaced when:
the → Maximum crack length: 0.5 x a mm (a = friction surface width in mm) is exceeded!
the → Maximum crack width: 1 mm is exceeded!
the → Maximum crack depth: 1.5 mm is exceeded!
WM 465002 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) > CHECKING >
CHECKING FRONT BRAKE DISC - MINIMUM THICKNESS
Information
Normally, brake discs are used until the maximum wear dimension is reached. → WM 4650TW
TECHNICAL DATA/BRAKE WEAR LIMITS Only in a few exceptional cases is it advisable to skim the
brake discs (if there is deep scoring or corrosion of the friction surface). In this case only the disc brake
dressing machines approved by Porsche AG are to be used .
Only as new brake discs may be reworked!
Only rework the brake discs symmetrically, evenly from both sides!
As the pressure force of a brake piston on the brake pad varies in magnitude, different areas of wear
arise on the friction surface. The brake disc can basically be divided into two areas of wear:
-A- Outer and inner wear area.
-B- Central wear area.
Fig 1: Identifying Front Brake Disc Minimum Thickness Wear Areas
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
The central wear area -B- is the area with the highest degree of wear.
Fig 2: Identifying Central Wear Areas
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Measure the brake discs using a suitable micrometer at least three different places (-A, B, C- ),
offset by 120°.
Fig 3: Measuring Brake Discs Using Suitable Micrometer
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465002 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) > CHECKING >
CHECKING LATERAL RUNOUT (BRAKE DISC/WHEEL HUB) AND THICKNESS
TOLERANCE
Information
Fasten dial gauge set with ball joint arm to wheel bearing housing.
Two adapters are used for checking lateral runout. The brake disc and wheel hub can be measured with
these.
Brake disc lateral runout
1. Remove wheel → 440519 REMOVING AND INSTALLING WHEEL
2. Adapter Plate 9510/1 must be fitted and tightened to Tightening Torque 160 Nm (118 ft. lb.).
→ Adapter plate on wheel hub
Fig 1: Identifying Adapter Plate On Wheel Hub
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Fit adapter Dial Gauge Set With Ball Joint Arm Nr. 147-1 at a suitable position on the wheel
bearing housing. → Dial gauge on brake disc
Fig 2: Installing Dial Gauge On Brake Disc
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Fit the dial gauge with some preload and measure the lateral runout at the greatest external
diameter of the brake disc.
Wheel hub lateral runout
Information
The front face of the wheel hub must not be corroded. If necessary, clean with fine emery cloth.
Measure the wheel hub lateral runout at the front face of the wheel hub. You should always
measure the external and internal diameters of the wheel bolt area.
1. Remove brake disc. → 465019 REMOVING AND INSTALLING FRONT BRAKE DISC
2. Fit adapter Dial Gauge Set With Ball Joint Arm Nr. 147-1 at a suitable position on the wheel
bearing housing. Fit the dial gauge with some preload. → Dial gauge on wheel hub
Fig 3: Installing Dial Gauge On Wheel Hub
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Brake disc thickness tolerance
For details of brake disc thickness tolerance, see Technical data/brake wear limits →. 4650TW
TECHNICAL DATA/BRAKE WEAR LIMITS
Measure the thickness tolerance using a suitable micrometer screw at approx. 8 places within the
braking surface.
WM 465019 REMOVING AND INSTALLING FRONT BRAKE DISC > TOOLS
Designation Type Number Description
Assembly Pin VW Tool T10439 For holding the
brake calliper
WM 465019 REMOVING AND INSTALLING FRONT BRAKE DISC > TECHNICAL
VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
No. 4: Cable M8 x 14 thread Tightening 20 Nm (15 ft.
cardiagn.com
holder to Torque lb.)
front-axle wheel
carrier
No. 5: Brake M6 x 12 thread Tightening 9 Nm (6.5 ft.
hose holder to Torque lb.)
front-axle wheel
carrier
No. 6: Fastening M12 x 1.5 thread Tightening 15 Nm (11 ft.
screw securing (always replace Torque lb.)
brake disc to screws and lock
wheel hub nuts after
removal)
Threaded M14 x 1.5 x 115 Tightening 140 Nm (104 ft.
connection thread (always Torque lb.)
securing brake replace screws
calliper to and lock nuts
front-axle after removal)
18-inch wheel
carrier
Threaded M14 x 1.5 x 135 Tightening 140 Nm (104 ft.
connection thread (always Torque lb.)
securing brake replace screws
calliper to and lock nuts
front-axle after removal)
19-inch wheel
carrier and
PCCB
WM 465019 REMOVING AND INSTALLING FRONT BRAKE DISC > PRELIMINARY
WORK
1. Raise the vehicle → 4X00IN LIFTING THE VEHICLE .
2. Remove wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND
INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465019 REMOVING AND INSTALLING FRONT BRAKE DISC > PRELIMINARY
WORK > REMOVING FRONT BRAKE DISC
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
NOTE: Removal of brake calliper
Paint defects on brake calliper
→ Proceed with care when setting back the brake pads.
→ Protect brake calliper from paint defects using a suitable cloth.
1. Expose lines.
Information
1. To gain better access for assembly work, it is a good idea to turn the wheels fully either to
the right or left!
1. 1.1. Remove fastening screws -1, 2- for holders -3, 4- for the brake hydraulic lines.
Fig 1: Identifying Brake Calliper Hydraulic Line Holders
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 1.2. Pull line for brake pad wear indicator out of the brake calliper.
3. 1.3. Disconnect plug connection for speed sensor.
Information
1. Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier .
2. Carefully press the brake pads back using water pump pliers. Remove a little brake fluid from
the reservoir by suction if necessary in order to prevent an overflow!
Information
1. Do not open the brake system .
2. Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
3. The core of the warning contact wire must not be left exposed! It does not matter if the
insulation is worn .
4. If necessary, remove a little brake fluid from the reservoir by suction in order to prevent
an overflow when the disc brake pads are pushed back .
3. Partially remove brake calliper. Use removal/installation aid for brake calliper Assembly Pin
T10439 .
Fig 2: Identifying Assembly Pin For Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 3.1. Remove upper fastening screw on the brake calliper -arrow- and insert
Assembly Pin.
Fig 3: Inserting Upper Assembly Pin
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Remove lower fastening screw on the brake calliper -arrow- and insert
Assembly Pin.
Fig 4: Inserting Lower Assembly Pin
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 3.3. Pull the brake calliper as far as required out of installation position until the brake
calliper engages in the cut-outs on the Assembly Pins → Brake calliper tool fitted .
Carefully guide brake line and brake hose along with calliper in the process.
Fig 5: Pulling Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Unscrew fastening screw -arrow- and remove brake disc.
Fig 6: Locating Brake Disc Fastening Screw
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465019 REMOVING AND INSTALLING FRONT BRAKE DISC > INSTALLING
FRONT BRAKE DISC
Information
Always replace the brake calliper fastening screws following removal!
Do not confuse right and left brake discs during assembly!
1. Check that all parts are in perfect condition (visual inspection) and replace them if necessary.
2. Clean the levelling and centering surfaces on the brake disc and wheel hub.
3. Apply a very thin coat of Optimoly TA to the centering surface on the wheel hub.
4. Installation is performed in reverse order.
Observe specified tightening torques:
Brake disc to wheel hub: Tightening Torque 15 Nm (11 ft. lb.)
Brake calliper to wheel bearing housing (18-inch brakes): Tightening Torque 140 Nm (104 ft.
lb.)
Brake calliper to wheel bearing housing (19-inch brakes): Tightening Torque 140 Nm (104 ft.
lb.)
Brake hose bracket to wheel bearing housing: Tightening Torque 9 Nm (6.5 ft. lb.)
Cable holder to wheel bearing housing: Tightening Torque 20 Nm (15 ft. lb.)
WM 465019 REMOVING AND INSTALLING FRONT BRAKE DISC > SUBSEQUENT
WORK
1. Position disc brake pads by operating the brake several times.
2. Check the brake fluid level and correct it if necessary.
3. Fit wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465019 REMOVING AND INSTALLING FRONT BRAKE DISC > SUBSEQUENT
WORK > INFORMATION ON BEDDING IN NEW BRAKE PADS
New brake pads require a slightly longer bedding-in period for PCCB brake discs than cast iron brake
discs.
In general, the following applies: New brake pads must be worn in (bedding-in period). Their optimum
braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking
effect must be compensated for by increased pressure on the brake pedal. The same also applies after
changing brake discs.
WM 4650TW TECHNICAL DATA/BRAKE WEAR LIMITS > TECHNICAL VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
Service brake Hydraulic
(footbrake) with dual-circuit brake
grey cast iron system with
brake discs brake-circuit
(standard brake) division per axle.
with PSM Vacuum brake
(Porsche Stability booster, internally
Management) as ventilated brake
standard discs with
six-piston
aluminum
cardiagn.com
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle.
PSM Porsche Stability
Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
Control (EDTC),
Automatic Brake
Differential
(ABD), brake
force boosting,
brake system
pre-filling.
Tandem brake 9/10 Zoll
booster Ø
(vacuum)
Boost ratio 8/7
Brake master 28.57 mm
cylinder Ø
Brake-circuit 24/12 mm
division
Brake disc Ø, 360 mm
front
Brake disc Ø, 330 mm
rear
Brake disc 36 mm
thickness, front
Brake disc 28 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.
cardiagn.com
Effective brake 294.4 mm
disc Ø, front
Effective brake 274.6 mm
disc Ø, rear
Piston Ø in front 6 x 36 mm
brake calliper
Piston Ø in rear 4 x 32 mm
brake calliper
Brake pad area, 480 cm2
front
Brake pad area, 200 cm2
rear
Total brake pad 680 cm2
area
Service brake Hydraulic
(footbrake) with dual-circuit brake
PCCB brake system with
discs with PSM brake-circuit
(Porsche Stability division per axle.
Management) as Vacuum brake
standard booster, internally
ventilated brake
discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle. The
brake callipers
are painted
yellow for visual
differentiation.
PSM Porsche Stability
Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
cardiagn.com
Control (EDTC),
Automatic Brake
Differential
(ABD), brake
force boosting,
brake system
pre-filling.
Tandem brake 9/10 Zoll
booster Ø
(vacuum)
Boost ratio 8/7
Brake master 28.57 mm
cylinder Ø
Brake-circuit 24/12 mm
division
Brake disc Ø, 390 mm
front
Brake disc Ø, 370 mm
rear
Brake disc 38 mm
thickness, front
Brake disc 30 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.
Effective brake 323 mm
disc Ø, front
Effective brake 314 mm
disc Ø, rear
Piston Ø in front 6 x 36 mm
brake calliper
Piston Ø in rear 4 x 32 mm
brake calliper
Brake pad area, 480 cm2
front
Brake pad area, 216 cm2
rear
Total brake pad 696 cm2
area
Pad thickness, Wear limit 2 mm approx. 9.7 mm
cardiagn.com
front
Pad thickness, Wear limit 2 mm approx. 8.8 mm
rear
Brake disc New 36 mm
thickness, front
Brake disc New 28 mm
thickness, rear
Brake disc Only as-new 35.6 mm
minimum brake discs may
thickness after be reworked!Only
machining, front rework the brake
disc
symmetrically,
evenly from both
sides!
Brake disc Only as-new 27.6 mm
minimum brake discs may
thickness after be reworked!Only
machining, rear rework the brake
disc
symmetrically,
evenly from both
sides!
Brake disc wear 34 mm
dimension, front
Brake disc wear 26 mm
dimension, rear
Peak-to-valley 0.006 mm
surface
roughness of
brake disc after
machining, max.
Thickness 0.02 mm
tolerance of
brake discs after
machining, max.
Lateral runout of 0.03 mm
brake disc, max.
Lateral runout of 0.02 mm
wheel hub, max.
Lateral runout of 0.06 mm
brake disc when
installed, max.
Pushrod play Not adjustable
cardiagn.com
Parking brake Drum brake
(foot-operated acting
parking brake) mechanically on
both rear wheels
Parking-brake Wear limit 211 210 mm
drum Ø mm
Brake shoe width 30 mm
Brake pad Wear limit 1 mm 3 mm
thickness
Pad thickness, Wear limit 2 mm approx. 8.6 mm
front
Pad thickness, Wear limit 2 mm approx. 8.9 mm
rear
Brake disc New 38 mm +0.1 mm -0.1 mm
thickness, front
Brake disc New 30 mm +0.1 mm -0.1 mm
thickness, rear
Brake disc wear Minimum brake mm(Read value
limit, front disc thickness on brake disc
(wear limit) is hub) XX.X
stamped on the
brake disc hub.
Example: Min.
Th. 37.7 mm
Brake disc wear Minimum brake mm(Read value
limit, rear disc thickness on brake disc
(wear limit) is hub) XX.X
stamped on the
brake disc hub.
Example: Min.
Th. 29.7 mm
Peak-to-valley New 0.006 mm
surface
roughness of
brake disc
Wear limit: Wear limit: Values and
Surface changes Connected procedure for:
in front and rear surface fracture > 46 51 02
brake discs 1 cm2 and/or Checking front
surface PCCB brake
roughness of discs/46 54 02
brake disc > 80 Checking rear
micrometer. PCCB brake
Replace PCCB discs.
brake discs on
cardiagn.com
both sides of the
axle.
Lateral runout of 0.03 mm
brake disc, max.
Lateral runout of 0.02 mm
wheel hub, max.
Lateral runout of 0.07 mm
brake disc when
installed, max.
Pushrod play Not adjustable
Parking brake Drum brake
(foot-operated acting
parking brake) mechanically on
both rear wheels
Parking-brake Wear limit 211 210 mm
drum Ø mm
Brake shoe width 30 mm
Brake pad Wear limit 1 mm 3 mm
thickness
WM 4650TW TECHNICAL DATA/BRAKE WEAR LIMITS > TECHNICAL VALUES >
TECHNICAL DATA - 18-INCH BRAKE SYSTEM (CAYENNE S/CAYENNE DIESEL
(U.S.A. ONLY)/CAYENNE DIESEL S/CAYENNE HYBRID)
Location Description Type Basic value Tolerance 1 Tolerance 2
Service brake Hydraulic
(footbrake) with dual-circuit brake
grey cast iron system with
brake discs brake-circuit
(standard brake) division per axle.
with PSM Vacuum brake
(Porsche Stability booster,
Management) as internally
standard ventilated brake
discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle.
cardiagn.com
PSM Porsche Stability
Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
Control (EDTC),
Automatic Brake
Differential
(ABD), brake
force boosting,
brake system
pre-filling.
Tandem brake 9/10 Zoll
booster Ø
(vacuum)
Boost ratio 8/7
Brake master 28.57 mm
cylinder Ø
Brake-circuit 24/12 mm
division
Brake disc Ø, 360 mm
front
Brake disc Ø, 330 mm
rear
Brake disc 36 mm
thickness, front
Brake disc 28 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.
Effective brake 294.4 mm
disc Ø, front
Effective brake 274.6 mm
disc Ø, rear
Piston Ø in front 6 x 36 mm
brake calliper
cardiagn.com
Piston Ø in rear 4 x 32 mm
brake calliper
Brake pad area, 480 cm2
front
Brake pad area, 200 cm2
rear
Total brake pad 680 cm2
area
WM 4650TW TECHNICAL DATA/BRAKE WEAR LIMITS > TECHNICAL VALUES >
TECHNICAL DATA - PCCB (CAYENNE BASIC MODEL/CAYENNE S/CAYENNE
DIESEL/CAYENNE DIESEL S/CAYENNE HYBRID)
Location Description Type Basic Value Tolerance 1 Tolerance 2
Service brake Hydraulic
(footbrake) with dual-circuit brake
PCCB brake system with
discs with PSM brake-circuit
(Porsche Stability division per axle.
Management) as Vacuum brake
standard booster, internally
ventilated brake
discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle. The
brake callipers
are painted
yellow for visual
differentiation.
PSM Porsche Stability
Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
cardiagn.com
Control (EDTC),
Automatic Brake
Differential
(ABD), brake
force boosting,
brake system
pre-filling.
Tandem brake 9/10 Zoll
booster Ø
(vacuum)
Boost ratio 8/7
Brake master 28.57 mm
cylinder Ø
Brake-circuit 24/12 mm
division
Brake disc Ø, 390 mm
front
Brake disc Ø, 370 mm
rear
Brake disc 38 mm
thickness, front
Brake disc 30 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.
Effective brake 323 mm
disc Ø, front
Effective brake 314 mm
disc Ø, rear
Piston Ø in front 6 x 36 mm
brake calliper
Piston Ø in rear 4 x 32 mm
brake calliper
Brake pad area, 480 cm2
front
Brake pad area, 216 cm2
rear
Total brake pad 696 cm2
area
WM 4650TW TECHNICAL DATA/BRAKE WEAR LIMITS > TECHNICAL VALUES > TEST
cardiagn.com
VALUES AND WEAR LIMITS FOR 18-INCH BRAKE SYSTEM (CAYENNE S/CAYENNE
DIESEL (U.S.A. ONLY)/CAYENNE DIESEL S/CAYENNE HYBRID)
Information
Depending on the extent of wear on cast iron brake discs, two condition criteria can make replacement
necessary:
Formation of cracks at advanced stage on the brake disc friction surfaces .
Minimum brake disc thickness is not retained due to wear (material erosion due to friction) . →
46500200 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) → 46530250 CHECKING
REAR BRAKE DISCS (WEAR ASSESSMENT)
Location Description Type Basic Value Tolerance 1 Tolerance 2
Pad thickness, Wear limit 2 mm approx. 9.7
front mm
Pad thickness, Wear limit 2 mm approx. 8.8
rear mm
Brake disc New 36 mm
thickness, front
Brake disc New 28 mm
thickness, rear
Brake disc Only as-new 35.6 mm
minimum brake discs may
thickness after be reworked!Only
machining, front rework the brake
disc
symmetrically,
evenly from both
sides!
Brake disc Only as-new 27.6 mm
minimum brake discs may
thickness after be reworked!Only
machining, rear rework the brake
disc
symmetrically,
evenly from both
sides!
Brake disc wear 34 mm
dimension, front
Brake disc wear 26 mm
dimension, rear
Peak-to-valley 0.006 mm
surface
roughness of
cardiagn.com
brake disc after
machining, max.
Thickness 0.02 mm
tolerance of
brake discs after
machining, max.
Lateral runout of 0.03 mm
brake disc, max.
Lateral runout of 0.02 mm
wheel hub, max.
Lateral runout of 0.06 mm
brake disc when
installed, max.
Pushrod play Not adjustable
Parking brake Drum brake
(foot-operated acting
parking brake) mechanically on
both rear wheels
Parking-brake Wear limit 211 210 mm
drum Ø mm
Brake shoe width 30 mm
Brake pad Wear limit 1 mm 3 mm
thickness
Possible complaints
Damage due to lack of use (rusting). This causes vibrations in the steering wheel, noises and
brake pedal pulsation.
Brake disc becomes distorted as a result of serious driving.
Too much lateral runout when new brake discs are fitted on dirty or distorted wheel hubs.
Procedure
Check brake disc for cracks, minimum thickness, lateral runout, thickness tolerance, flatness and
surface roughness.
If necessary, (depending on the actual brake disc thickness and the brake disc wear limit) machine
the brake disc using one of the disc brake dressing machines approved by Porsche.
The brake disc must only be reworked symmetrically, i.e. evenly from both sides! Read the
operating instructions for the disc brake dressing machine!
WM 4650TW TECHNICAL DATA/BRAKE WEAR LIMITS > TECHNICAL VALUES > TEST
VALUES AND WEAR LIMITS FOR PCCB (CAYENNE BASIC MODEL/CAYENNE
S/CAYENNE DIESEL/CAYENNE DIESEL S/CAYENNE HYBRID)
Information
cardiagn.com
The following condition criteria can make replacement necessary depending on the wear of the PCCB
brake discs:
Surface changes in the brake disc friction surfaces at an advanced stage .
Minimum brake disc thickness is not retained due to wear (material erosion due to friction) .
Information
The PCCB brake disc must not be machined.
Location Description Type Basic Value Tolerance 1 Tolerance 2
Pad thickness, Wear limit 2 mm approx. 8.6 mm
front
Pad thickness, Wear limit 2 mm approx. 8.9 mm
rear
Brake disc New 38 mm +0.1 mm -0.1 mm
thickness, front
Brake disc New 30 mm +0.1 mm -0.1 mm
thickness, rear
Brake disc wear Minimum brake mm (Read
limit, front disc thickness value on brake
(wear limit) is disc hub) XX.X
stamped on the
brake disc hub.
Example: Min.
Th. 37.7 mm
Brake disc wear Minimum brake mm (Read
limit, rear disc thickness value on brake
(wear limit) is disc hub) XX.X
stamped on the
brake disc hub.
Example: Min.
Th. 29.7 mm
Peak-to-valley New 0.006 mm
surface
roughness of
brake disc
Wear limit: Wear limit: Values and
Surface changes Connected procedure for:
in front and rear surface fracture 46 51 02
brake discs > 1 cm2 and/or Checking front
surface PCCB brake
roughness of discs/46 54 02
brake disc > 80 Checking rear
micrometer. PCCB brake
Replace PCCB discs.
brake discs on
cardiagn.com
both sides of the
axle.
Lateral runout of 0.03 mm
brake disc, max.
Lateral runout of 0.02 mm
wheel hub, max.
Lateral runout of 0.07 mm
brake disc when
installed, max.
Pushrod play Not adjustable
Parking brake Drum brake
(foot-operated acting
parking brake) mechanically on
both rear wheels
Parking-brake Wear limit 211 210 mm
drum Ø mm
Brake shoe width 30 mm
Brake pad Wear limit 1 mm 3 mm
thickness
Possible complaints
Too much lateral runout when new brake discs are fitted on dirty or distorted wheel hubs.
Procedure
Check brake disc for minimum thickness, lateral runout, thickness tolerance, flatness and surface
roughness.
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > NOTE ON
PICTURES SHOWN
Information
The pictures shown in this document may differ from the original .
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > GENERAL
INFORMATION ON PCCB BRAKE DISCS
The brake discs have wear indicator plates in the friction surfaces. The wear indicator plates (six on
each brake disc) are arranged close to the outer diameter, offset by 120 ° -arrows- at three points. The
three wear indicator plates on each friction surface (3 on the inside and 3 on the outside) are positioned
directly opposite each other. Each wear indicator is approx. 2 cm2 . The wear indicators are barely
visible on new brake discs.
Fig 1: Locating Brake Discs Wear Indicators
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
The minimum brake disc thickness (wear dimension) is stamped on the brake-disc chamber (e.g. Min.
Th. 37.7 mm).
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > BASIC
INFORMATION
Checking involves the following: Information
1. Visual inspection for surface changes in the brake disc friction surfaces and wear indicators.
Indication of wear: Connected surface fracture > 1 cm2-arrow- , without adding up smaller
fractures → 465102 CHECKING FRONT PCCB BRAKE DISCS (WEAR ASSESSMENT) -
section on "Checking".
Fig 1: Locating Brake Discs Surface Fracture
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
cardiagn.com
2. Check surface roughness (Rk) of brake discs (max. 80 μm permitted) since this affects braking
comfort (noises), braking behavior/pedal pressure and brake-pad service life → 465102
CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Checking".
Fig 2: Identifying Surface Roughness Of PCCB Brake Disc
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Check brake discs for minimum thickness -X- . The minimum brake disc thickness (e.g. Min.
Th. 37.7 mm) is stamped on the brake-disc chamber → 465102 CHECKING FRONT PCCB
BRAKE DISC (WEAR ASSESSMENT) - section on "Checking".
Fig 3: Identifying Minimum Thickness Of PCCB Brake Disc
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Check brake discs for edge damage -see pictureFig 4- (damage due to improper use) →
465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) - section on
"Checking".
Fig 4: Identifying PCCB Brake Disc Damage Edge
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
cardiagn.com
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > GENERAL
INFORMATION ON REPLACING WORN PCCB BRAKE DISCS
Three criteria governing the condition of the parts can make replacement necessary depending
on the wear of PCCB brake discs:
1. Surface changes in the brake disc friction surfaces (material fatigue/wear) at an advanced
stage (indication of wear: connected friction surface damage > 1 cm2 ).
2. Surface roughness of the brake disc friction surfaces too great (roughness depends on
mileage and load).
3. Brake disc minimum thickness is not attained due to wear (material erosion due to friction).
1. In practice, all three forms of brake disc erosion usually occur.
2. Only in rare cases (as a result of long-term motor-racing brake loads/very high
temperatures on the friction surfaces), surface changes can progress so quickly that the
brake discs may need to be changed earlier than planned.
3. Brake discs that have turned blue at the brake-disc chamber and/or brake callipers that
have turned a strong brown color are clear indications of high loads over a long period of
time, e.g. on the race circuit.
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > REPLACING
BRAKE DISCS (INSTRUCTIONS/DECISION-MAKING AID)
cardiagn.com
When replacing brake discs as a result of wear (see wear assessment) both brake discs must be
replaced on an axle!
Irrespective of wear, a brake disc change may be necessary due to edge damage on the brake disc
friction surfaces! In this case, only one brake disc can be replaced if the friction surface of the other
PCCB brake disc is still 'as new' → 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR
ASSESSMENT) - section on "Checking".
The wear indicator plates (six on each brake disc) are arranged close to the outer diameter, offset by
120 ° -arrows- at three points. The three wear indicator plates on each friction surface (3 on the inside
and 3 on the outside) are positioned directly opposite each other. Each wear indicator is approx. 2 cm2 .
The wear indicators are barely visible on new brake discs.
Fig 1: Locating Wear Indicators
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
The minimum brake disc thickness (wear dimension) is stamped on the brake-disc chamber (e.g. Min.
Th. 37.7 mm).
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > CRACKS (STRESS-
RELIEF MICROSTRUCTURE) IN THE BRAKE DISC FRICTION SURFACE
Cracks in the brake disc friction surfaces must be regarded differently to cracks in grey cast-iron brake
discs. These cracks are not regarded as wear criteria for PCCB brake discs and may even be present
on new brake discs, depending on the manufacturer.
Fig 1: Identifying Stress-Relief Microstructure In PCCB Brake Disc Friction Surfaces
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
Due to the composition of different materials in the friction layer and support body, the friction
surfaces (even when new) are coated with an uncritical crack pattern (stress-relief microstructure).
Individual relaxation cracks sometimes run along the perforated bores .
The stress-relief microstructure results from the way in which the brake disc surface is
manufactured and does not pose a risk to safety. There is also no danger of the friction layers
flaking off from the support body, since the friction layers are almost free of internal stresses as a
result of the stress-relief microstructure .
The stress-relief microstructure is sometimes clearly visible in new brake discs and the brake disc
chamber side and the side that is opposite to the chamber can differ significantly from one another
.
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > INFORMATION
CONCERNING BORES (PERFORATIONS) IN THE BRAKE DISC FRICTION SURFACE
Observe the following warning when cleaning or exposing the bores in the brake disc friction surface!
Fig 1: Identifying Bores (Perforations) In Brake Disc Friction Surface
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
NOTE: Work cannot be carried out on the bores in the brake disc friction surface
Damage to brake discs
→ Clean the bores on PCCB brake discs with high-pressure cleaning equipment if necessary. Observe
the relevant environmental and safety regulations.
→ Do not machine the bores. Drilling or counter-sinking is not permitted.
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > COATING ON THE
PCCB BRAKE DISCS (POTENTIAL CAUSES)
The coating on the PCCB brake discs arises as a result of a high load and high temperatures, for
example on a racing circuit. Check the following in such cases:
Fig 1: Identifying Bores (Perforations) In Brake Disc Friction Surface
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Ventilation (brake cooling): all components are present, secured correctly and undamaged.
Brake pad quality: If the vehicle is used for race-track driving, use appropriate brake pads.
The perforation bores -see pictureFig 1- in the brake discs must not be blocked. Unblock them if
necessary. → 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) - section
on "Information".
In the event of brake pad wear, the brake discs can still be used provided the brake discs satisfy all
wear criteria (see also GENERAL INFORMATION ON REPLACEMENT OF PCCB BRAKE DISCS
DUE TO WEAR ). The perforation bores -see pictureFig 1- must not be blocked.
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > INFORMATION ON
BEDDING IN NEW BRAKE PADS
New brake pads require a slightly longer bedding-in period for PCCB brake discs than cast iron brake
discs.
In general, the following applies: New brake pads must be broken in (bedding-in period), their optimum
cardiagn.com
braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking
effect must be compensated for by increased pressure on the brake pedal. The same also applies after
a brake disc change.
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING PCCB BRAKE DISCS (WEAR ASSESSMENT) > VISUAL INSPECTION OF
THE SURFACES OF THE BRAKE DISC FRICTION SURFACES (INDICATION OF
WEAR)
Information
The friction surface changes occur due to material fatigue as a result of extremely high thermal
load. These disc temperatures, which occur above all in racing conditions, cause a progressive
material fatigue .
Effects on driving: The surface change worsens the smoothness of braking, decreases the disc
strength and increases the brake pad wear and therefore makes a precautionary parts
replacement necessary .
The following illustrations (PCCB brake disc wear appearance) are to be used for damage assessment.
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING PCCB BRAKE DISCS (WEAR ASSESSMENT) > PCCB BRAKE DISC
WEAR APPEARANCE
1. Friction surfaces after normal brake load while driving on roads. No surface fractures present -
Brake discs do not need to be replaced!
Fig 1: Identifying PCCB Brake Disc Wear Appearance
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Friction surfaces after a long journey and occasional high load. Isolated cases of connected
surface fractures less than 1 cm2-arrow- .
No replacement necessary as the connected surface fractures are < 1 cm2 !
Fig 2: Locating PCCB Surface Fractures
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. End of service life of friction surface or after highest load on a racing circuit.
Replace brake discs if the connected friction surface damage is > 1 cm2-arrow- . To do this,
follow the instructions provided under → 465102 CHECKING FRONT PCCB BRAKE DISC
(WEAR ASSESSMENT) - section on "Information".
Fig 3: Locating PCCB Friction Surface Damage
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
The best way to detect a surface fracture is by checking the wear indicators. Based on the
wear indicators, this means that at least one wear indicator -arrow- must have a surface
fracture of > 50% (damage > 1 cm2 /entire surface of a wear indicator with a surface area of
approx. 2 cm2 ).
Fig 4: Locating PCCB Surface Fracture On Wear Indicator
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING PCCB BRAKE DISCS (WEAR ASSESSMENT) > EVALUATION OF
SURFACE ROUGHNESS RK (MAX. 80 MICROMETERS PERMITTED)
Information
An increase in surface roughness impairs smoothness of braking (rubbing, shaking in steering
wheel, scraping noises) and increases brake pad wear .
With a roughness (Rk) value of > 80 μm (> 80 micrometers), a precautionary parts replacement is
required .
The assessment is carried out visually, based on the diagram. Two illustrations of the same peak-to-
valley surface roughness (views 1 and 2) help to make a better assessment.
1. Brake discs that are OK:
1. 1.1. Surface roughness (Rk) = 6 μm -see picture- (view 1)Fig 1
Fig 1: Identifying PCCB Surface Roughness 6 Micrometers (View 1)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Surface roughness (Rk) = 6 μm -see picture- (view 2)Fig 2
New brake disc. Illustration is used for better classification.
The early stages of roughness are indicated by burnt-out carbon fibres on the
surface of an otherwise intact, semi-matt surface.
The surface feels smooth.
Fig 2: Identifying PCCB Surface Roughness 6 Micrometers (View 2)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 1.2. Surface roughness (Rk) = 56 μm -see picture- (view 1)Fig 3
Fig 3: Identifying PCCB Surface Roughness 56 Micrometers (View 1)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Surface roughness (Rk) = 56 μm -see picture- (view 2)Fig 4
In the advanced stages of fibre burnout and the initial destruction of the Si and SiC
'matrix', the depressions have become more pronounced. Large sections of the
surface are still intact, the depressions form an even, fine-grained pattern.
The surface still feels matt, however, and the roughness is not yet pronounced.
Fig 4: Identifying PCCB Surface Roughness 56 Micrometers (View -2)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
No replacement necessary!
3. 1.3. Surface roughness (Rk) = 72 μm -see picture- (view 1)Fig 5
Fig 5: Identifying PCCB Surface Roughness 72 Micrometers (View 1)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Surface roughness (Rk) = 72 μm -see picture- (view 2)Fig 6
Borderline disc, which can still just be evaluated as OK. As a result of more
advanced damage to the surface, the depressions are larger, and above all deeper,
compared with the previous surface condition.
On the one hand, the more extensive roughness is noticeable (only when a
comparison is made); on the other hand, however, like before, "only" depressions are
observed.
Replacement not yet necessary!
Fig 6: Identifying PCCB Surface Roughness 72 Micrometers (View 2)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Worn brake discs:
1. 2.1. Surface roughness (Rk) = 108 μm -see picture- (view 1)Fig 7
Fig 7: Identifying PCCB Surface Roughness 108 Micrometers (View 1)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Surface roughness (Rk) = 108 μm -see picture- (view 2)Fig 8
Worn surface. Advanced wear has led to a situation where only the remains of the
original surface are left.
It is clear that the roughness is caused not only by depressions but also by bumps.
Replace brake discs! To do this, follow the instructions → 465102 CHECKING
FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Information".
In general, the following applies: Brake discs must be replaced if the surface
roughness (Rk) is > 80 μm!
Fig 8: Identifying PCCB Surface Roughness 108 Micrometers (View 2)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Worn brake discs (special cases):
1. 3.1. Surface roughness (Rk) = 108 μm, as for previous disc, but with some of the
original friction surface remaining -arrow- .
Replace brake discs! To do this, follow the instructions → 465102 CHECKING
FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Information".
In general, the following applies: Brake discs must be replaced if the surface
roughness (Rk) is > 80 μm!
Fig 9: Identifying PCCB Surface Roughness (108 Micrometers)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Surface roughness (Rk) = 72 μm. Borderline disc, identified by the roughness,
but also by the indication of wear and connected surface fractures -arrows- , > 1
cm2 .
Replace brake discs! To do this, follow the instructions provided under → 465102
CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) - section on
"Information".
Fig 10: Identifying Defective PCCB Brake Disc
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING PCCB BRAKE DISCS (WEAR ASSESSMENT) > CHECKING BRAKE DISCS
FOR MINIMUM THICKNESS
Information
For perforated brake discs, the minimum thickness -X- must always be measured on the inner or
outer friction surface track -arrows- .
Fig 1: Identifying Minimum Thickness Of PCCB Brake Disc
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Wear limit: The minimum brake disc thickness is stamped on the brake-disc chamber (e.g. Min. Th.
37.7 mm) .
Measure the brake thickness -X- with a suitable micrometer screw gauge or a brake disc gauge
around the inner or outer friction surface tracks -arrows- .
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING PCCB BRAKE DISCS (WEAR ASSESSMENT) > CHECKING BRAKE DISCS
FOR EDGE DAMAGE
Information
Irrespective of wear, a brake disc change may be necessary due to edge damage on the brake
disc friction surfaces .
In such cases, only one brake disc may need to be replaced if the friction surface of the other
PCCB brake disc is still perfectly OK .
Fig 1: Checking PCCB Brake Disc Edge Damage
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Max. permissible width/depth = 2 mm
Max. permitted length = 10 mm
Max. 3 damaged edge areas permissible
WM 465119 REMOVING AND INSTALLING FRONT BRAKE DISC (PCCB) > TOOLS
Designation Type Number Description
Assembly Pin VW Tool T10439 For holding the
brake calliper
WM 465119 REMOVING AND INSTALLING FRONT BRAKE DISC (PCCB) >
TECHNICAL VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
cardiagn.com
No. 4: Cable M8 x 14 thread Tightening 20 Nm (15 ft.
holder to Torque lb.)
front-axle wheel
carrier
No. 5: Brake M6 x 12 thread Tightening 9 Nm (6.5 ft.
hose holder to Torque lb.)
front-axle wheel
carrier
No. 6: Fastening M12 x 1.5 thread Tightening 15 Nm (11 ft.
screw securing (always replace Torque lb.)
brake disc to screws and lock
wheel hub nuts after
removal)
Threaded M14 x 1.5 x 135 Tightening 140 Nm (104 ft.
connection thread (always Torque lb.)
securing brake replace screws
calliper to and lock nuts
front-axle after removal)
19-inch wheel
carrier and
PCCB
WM 465119 REMOVING AND INSTALLING FRONT BRAKE DISC (PCCB) >
PRELIMINARY WORK
1. Raise the vehicle → 4X00IN LIFTING THE VEHICLE .
2. Remove wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND
INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465119 REMOVING AND INSTALLING FRONT BRAKE DISC (PCCB) >
PRELIMINARY WORK > REMOVING FRONT BRAKE DISC (PCCB)
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
NOTE: Removal of brake calliper
Paint defects on brake calliper
→ Proceed with care when setting back the brake pads.
→ Protect brake calliper from paint defects using a suitable cloth.
1. Expose lines.
Information
1. To gain better access for assembly work, it is a good idea to turn the wheels fully either to
the right or left!
1. 1.1. Remove fastening screws -1, 2- for holders -3, 4- for the brake hydraulic lines.
Fig 1: Identifying Hydraulic Line Holders
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 1.2. Pull line for brake pad wear indicator out of the brake calliper.
3. 1.3. Disconnect plug connection for speed sensor.
Information
1. Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier .
2. Carefully press the brake pads back using water pump pliers. Remove a little brake fluid from
the reservoir by suction if necessary in order to prevent an overflow!
Information
1. Do not open the brake system .
2. Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
3. The core of the warning contact wire must not be left exposed! It does not matter if the
insulation is worn .
4. If necessary, remove a little brake fluid from the reservoir by suction in order to prevent
an overflow when the disc brake pads are pushed back .
3. Partially remove brake calliper. Use removal/installation aid for brake calliper Assembly Pin
T10439 .
Fig 2: Identifying Assembly Pin For Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 3.1. Remove upper fastening screw on the brake calliper -arrow- and insert
Assembly Pin.
Fig 3: Inserting Upper Assembly Pin
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Remove lower fastening screw on the brake calliper -arrow- and insert
Assembly Pin.
Fig 4: Inserting Lower Assembly Pin
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 3.3. Pull the brake calliper as far as required out of installation position until the brake
calliper engages in the cut-outs on the Assembly Pins → Brake calliper tool fitted .
Carefully guide brake line and brake hose along with calliper in the process.
Fig 5: Pulling Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Unscrew fastening screw -arrow- and remove brake disc.
Fig 6: Locating Brake Disc Fastening Screw
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465119 REMOVING AND INSTALLING FRONT BRAKE DISC (PCCB) >
INFORMATION > EXPLANATION OF TWO-PART BRAKE DISC
The PCCB brake discs consist of two parts on the front and rear axles. The brake disc -1- is
screwed to the brake disc hub -2- with 10 screws (M6) -3- .
Only the complete brake disc is available as a spare part (disc + brake disc hub)!
Do not separate the brake disc hub -2- and brake disc -1- .
Do not attempt to turn the screws -3- . The screws are prevented from turning by compression in
the bush.
Changing the Tightening Torque of the screws -3- will have negative effects on the noise
produced.
Fig 1: Identifying Two-Part Brake Disc
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465119 REMOVING AND INSTALLING FRONT BRAKE DISC (PCCB) >
INSTALLING FRONT BRAKE DISC > INSTALLING FRONT BRAKE DISC (PCCB)
Information
Always replace the brake calliper fastening screws following removal!
Do not confuse right and left brake discs during assembly!
1. Check that all parts are in perfect condition (visual inspection) and replace them if necessary.
2. Clean the levelling and centering surfaces on the brake disc and wheel hub.
3. Apply a very thin coat of Optimoly TA to the centering surface on the wheel hub.
4. Installation is performed in reverse order.
Observe specified tightening torques:
Brake disc to wheel hub: Tightening Torque 15 Nm (11 ft. lb.)
Brake calliper to wheel bearing housing: Tightening Torque 140 Nm (104 ft. lb.)
Brake hose bracket to wheel carrier: Tightening Torque 9 Nm (6.5 ft. lb.)
Cable holder to wheel carrier: Tightening Torque 20 Nm (15 ft. lb.)
WM 465119 REMOVING AND INSTALLING FRONT BRAKE DISC (PCCB) >
SUBSEQUENT WORK
1. Position disc brake pads by operating the brake several times.
2. Check the brake fluid level and correct it if necessary.
3. Fit wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
Courtesy of PORSCHE CARS NORTH AMERICA, INC. cardiagn.com
WM 465119 REMOVING AND INSTALLING FRONT BRAKE DISC (PCCB) >
SUBSEQUENT WORK > INFORMATION ON BEDDING IN NEW BRAKE PADS
New brake pads require a slightly longer bedding-in period for PCCB brake discs than cast iron brake
discs.
In general, the following applies: New brake pads must be worn in (bedding-in period). Their optimum
braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking
effect must be compensated for by increased pressure on the brake pedal. The same also applies after
changing brake discs.
WM 465119 REMOVING AND INSTALLING FRONT PCCB BRAKE DISC > TOOLS
Designation Type Number Description
Assembly Pin VW Tool T10439 For holding the
brake calliper
cardiagn.com
WM 465119 REMOVING AND INSTALLING FRONT PCCB BRAKE DISC >
INFORMATION > NOTE ON PICTURES SHOWN
Information
The pictures shown in this document may differ from the original .
WM 465119 REMOVING AND INSTALLING FRONT PCCB BRAKE DISC >
PRELIMINARY WORK
1. Raise the vehicle → 4X00IN LIFTING THE VEHICLE .
2. Remove wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND
INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465119 REMOVING AND INSTALLING FRONT PCCB BRAKE DISC >
PRELIMINARY WORK > REMOVING FRONT BRAKE DISC (PCCB)
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
NOTE: Removal of brake calliper
Paint defects on brake calliper
→ Proceed with care when setting back the brake pads.
→ Protect brake calliper from paint defects using a suitable cloth.
1. Expose lines.
Information
1. To gain better access for assembly work, it is a good idea to turn the wheels fully either to
the right or left!
1. 1.1. Remove fastening screws -1, 2- for holders -3, 4- for the brake hydraulic lines.
Fig 1: Identifying Brake Calliper Hydraulic Line Holders
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 1.2. Pull line for brake pad wear indicator out of the brake calliper.
3. 1.3. Disconnect plug connection for speed sensor.
Information
1. Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier .
2. Carefully press the brake pads back using water pump pliers. Remove a little brake fluid from
the reservoir by suction if necessary in order to prevent an overflow!
Information
1. Do not open the brake system .
2. Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
3. The core of the warning contact wire must not be left exposed! It does not matter if the
insulation is worn .
4. If necessary, remove a little brake fluid from the reservoir by suction in order to prevent
an overflow when the disc brake pads are pushed back .
3. Partially remove brake calliper. Use removal/installation aid for brake calliper Assembly Pin
T10439 .
Fig 2: Identifying Assembly Pin For Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 3.1. Remove upper fastening screw on the brake calliper -arrow- and insert
Assembly Pin.
Fig 3: Inserting Upper Assembly Pin
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Remove lower fastening screw on the brake calliper -arrow- and insert
Assembly Pin.
Fig 4: Inserting Lower Assembly Pin
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 3.3. Pull the brake calliper as far as required out of installation position until the brake
calliper engages in the cut-outs on the Assembly Pins → Brake calliper tool fitted .
Carefully guide brake line and brake hose along with calliper in the process.
Fig 5: Pulling Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Unscrew fastening screw -arrow- and remove brake disc.
Fig 6: Locating Brake Disc Fastening Screw
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465119 REMOVING AND INSTALLING FRONT PCCB BRAKE DISC >
INFORMATION > EXPLANATION OF TWO-PART BRAKE DISC
1. The PCCB brake discs consist of two parts on the front and rear axles. The brake disc -1- is
screwed to the brake-disc chamber -2- with screws (M6) -3- .
Fig 1: Identifying Two-Part Brake Disc
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fig 2: Identifying Two-Part Brake Disc
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Only the complete brake disc is available as a spare part (disc + brake-disc chamber)!
3. Do not separate the brake-disc chamber -2- and brake disc -1- . In addition, the screws -3-
must not be turned and should not need to be turned. The screws are prevented from turning
by compression in the bushing.
4. It is essential that the Tightening Torque of the screws is not changed (do not turn the screws)
as this can have a negative effect on the sound behavior.
1 Brake disc
2 Brake-disc chamber
3 Screw
WM 465119 REMOVING AND INSTALLING FRONT PCCB BRAKE DISC > INSTALLING
FRONT BRAKE DISC > INSTALLING FRONT BRAKE DISC (PCCB)
Information
Always replace the brake calliper fastening screws following removal!
Do not confuse right and left brake discs during assembly!
1. Check that all parts are in perfect condition (visual inspection) and replace them if necessary.
2. Clean the levelling and centering surfaces on the brake disc and wheel hub.
3. Apply a very thin coat of Optimoly TA to the centering surface on the wheel hub.
4. Installation is performed in reverse order.
Observe specified tightening torques:
Brake disc to wheel hub:
Brake calliper to wheel bearing housing:
Brake hose bracket to wheel carrier:
Cable holder to wheel carrier:
WM 465119 REMOVING AND INSTALLING FRONT PCCB BRAKE DISC >
SUBSEQUENT WORK
cardiagn.com
1. Fit the wheel. Use assembly aids (Assembly Pins) -1- . → 44051900 REMOVING AND
INSTALLING WHEEL
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465119 REMOVING AND INSTALLING FRONT PCCB BRAKE DISC >
SUBSEQUENT WORK > INFORMATION ON BEDDING IN NEW BRAKE PADS
New brake pads require a slightly longer bedding-in period for PCCB brake discs than cast iron brake
discs.
In general, the following applies: New brake pads must be worn in (bedding-in period). Their optimum
braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking
effect must be compensated for by increased pressure on the brake pedal. The same also applies after
changing brake discs.
WM 465302 CHECKING REAR BRAKE DISCS (WEAR ASSESSMENT) > TOOLS
Designation Type Number Description
Adapter Plate Special Tool 9510/1
Dial Gauge Set Commercially Nr. 147-1
with Ball Joint Available Tool
Arm
cardiagn.com
WM 465302 CHECKING REAR BRAKE DISCS (WEAR ASSESSMENT) > TECHNICAL
VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
Brake discs Maximum crack 0.5 x a mm
length
Brake discs Maximum crack 1 mm
width
Brake discs Maximum crack 1.5 mm
depth
WM 465302 CHECKING REAR BRAKE DISCS (WEAR ASSESSMENT) >
INFORMATION > NOTE ON PICTURES SHOWN
Information
The pictures shown in this document may differ from the original .
WM 465302 CHECKING REAR BRAKE DISCS (WEAR ASSESSMENT) >
INFORMATION > BRAKE DISC WEAR ASSESSMENT - GENERAL
Normally, brake disc replacement is necessary after the thickness falls below the minimum. In rare,
isolated cases (of very high loads for long periods) replacement may be necessary due to crack
formation. To a certain extent these cracks may be rated as not important. A description is given in the
following sections of when to replace brake discs.
Cracks occur as a result of material fatigue due to frequent and extreme thermal expansion fluctuations.
Particularly in cases of very high loads for long periods, these thermal expansion fluctuations produce
internal stresses. The result may be cracks in the friction surface. These cracks allow relaxation of the
friction disc, so that the speed at which the cracks develop is very slow.
Cracks run from the centre of the friction surface to the (inner and outer) edges of the brake disc. As
different vehicle types have different brake disc sizes, differences arise for the maximum crack length
limits.
Maximum crack length limit is calculated as follows:
0.5 x a (-a- = width of friction surface in mm).
Fig 1: Identifying Brake Disc Friction Surface Width
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Larger cracks impair braking comfort and reduce brake disc strength, therefore making brake disc
replacement necessary as a precaution.
Irrespective of the crack length, the brake disc must be replaced if the crack has extended as far as the
outer and/or inner edge of the disc.
WM 465302 CHECKING REAR BRAKE DISCS (WEAR ASSESSMENT) >
INFORMATION > BEDDING IN THE BRAKE PADS AND BRAKE DISCS
New brake pads require a bedding-in period of approx. 200 km (124 miles)! Only then do they achieve
their best friction and wear coefficient. During this period, the brakes should be subjected to full stress
when travelling at high speed only in emergencies. The slightly reduced braking effect must be
compensated for by increased pressure on the brake pedal. The same also applies after replacing or
machining brake discs.
WM 465302 CHECKING REAR BRAKE DISCS (WEAR ASSESSMENT) > CHECKING
REAR BRAKE DISCS (EVALUATING CRACKS)
Different vehicle types have different brake disc sizes. This results in differences in terms of maximum
crack length limits.
Maximum crack length limit is calculated as follows:
0.5 x a (-a- = width of friction surface in mm).
Fig 1: Identifying Rear Brake Discs Friction Surface Width
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
The length of a crack can be measured with a steel rule, for example. → Brake discs
Fig 2: Measuring Rear Brake Discs Friction Surface Cracks
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
Irrespective of the crack length, the brake disc must be replaced if the crack has extended as far as the
outer and/or inner edge of the disc.
As a precaution, brake discs must be replaced when:
the → Maximum Crack Length: 0.5 x a mm (a = friction surface width in mm) is exceeded!
the → Maximum Crack Width: 1 mm is exceeded!
the → Maximum Crack Depth: 1.5 mm is exceeded!
WM 465302 CHECKING REAR BRAKE DISCS (WEAR ASSESSMENT) > CHECKING
REAR BRAKE DISCS (EVALUATING CRACKS) > CHECKING REAR BRAKE DISCS
(MINIMUM THICKNESS)
Information
Normally, brake discs are used until the maximum wear dimension is reached. → WM 4650TW
TECHNICAL DATA/BRAKE WEAR LIMITS Only in a few exceptional cases is it advisable to skim the
brake discs (if there is deep scoring or corrosion of the friction surface). In this case only the disc brake
dressing machines approved by Porsche AG are to be used .
Only as new brake discs may be reworked!
Only rework the brake discs symmetrically, evenly from both sides!
As the pressure force of a brake piston on the brake pad varies in magnitude, different areas of wear
arise on the friction surface. The brake disc can basically be divided into two areas of wear:
-A- Outer and inner wear area.
-B- Central wear area.
Fig 1: Identifying Rear Brake Discs Wear Areas A And B (Minimum Thickness)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
The central wear area -B- is the area with the highest degree of wear.
Fig 2: Identifying Rear Brake Discs Wear Areas B (Minimum Thickness)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Measure the brake discs using a suitable micrometer at least three different places (-A, B, C- ),
offset by 120°.
Fig 3: Measuring Brake Discs Using Suitable Micrometer
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465302 CHECKING REAR BRAKE DISCS (WEAR ASSESSMENT) > CHECKING
REAR BRAKE DISCS (EVALUATING CRACKS) > CHECKING LATERAL RUNOUT
(BRAKE DISC/WHEEL HUB) AND THICKNESS TOLERANCE
Information
Fasten dial gauge set with ball joint arm to wheel bearing housing.
Two adapters are used for checking lateral runout. The brake disc and wheel hub can be measured with
these.
Brake disc lateral runout
1. Remove wheel → 440519 REMOVING AND INSTALLING WHEEL
2. Adapter Plate 9510/1 must be fitted and tightened to Tightening Torque 160 Nm (118 ft. lb.).
→ Adapter plate on wheel hub
Fig 1: Identifying Adapter Plate On Wheel Hub
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Fit adapter Dial Gauge Set With Ball Joint Arm Nr. 147-1 at a suitable position on the wheel
bearing housing. → Dial gauge on brake disc
Fig 2: Fitting Adapter Dial Gauge Set With Ball Joint
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Fit the dial gauge with some preload and measure the lateral runout at the greatest external
diameter of the brake-disc.
Wheel hub lateral runout
Information
The front face of the wheel hub must not be corroded. If necessary, clean with fine emery cloth.
Measure the wheel hub lateral runout at the front face of the wheel hub. You should always
measure the external and internal diameters of the wheel bolt area.
1. Remove brake disc. → 465319 REMOVING AND INSTALLING REAR BRAKE DISC
2. Fit adapter Dial Gauge Set With Ball Joint Arm Nr. 147-1 at a suitable position on the wheel
bearing housing. Fit the dial gauge with some preload. → Dial gauge on wheel hub
Fig 3: Measuring Wheel Hub Lateral Runout Using Dial Gauge
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Brake disc thickness tolerance
For details of brake disc thickness tolerance, see Technical data/brake wear limits →. 4650TW
TECHNICAL DATA/BRAKE WEAR LIMITS
Measure the thickness tolerance using a suitable micrometer screw at approx. 8 places within the
braking surface.
WM 465319 REMOVING AND INSTALLING REAR BRAKE DISC > TOOLS
Designation Type Number Description
PIWIS Tester II Special Tool 9818
WM 465319 REMOVING AND INSTALLING REAR BRAKE DISC > TECHNICAL
VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
No. 7: Fastening M12 x 1.5 thread Tightening 15 Nm (11 ft.
cardiagn.com
screw securing (always replace Torque lb.)
brake disc to screws and lock
wheel hub nuts after
removal)
No. 10: ABS M6 x 12 thread Tightening 8 Nm (6 ft. lb.)
cable holder to Torque
rear-axle wheel
carrier
Threaded M12 x 1.5 x 115 Tightening 85 Nm (63 ft.
connection thread (always Torque lb.)
securing brake replace screws
calliper to and lock nuts
rear-axle wheel after removal)
carrier
WM 465319 REMOVING AND INSTALLING REAR BRAKE DISC > PRELIMINARY
WORK
1. Raise the vehicle → 4X00IN LIFTING THE VEHICLE .
2. Remove wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND
INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465319 REMOVING AND INSTALLING REAR BRAKE DISC > REMOVING REAR
BRAKE DISC
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
1. PIWIS Tester II 9818 must be connected and started.
1. 1.1. Select Parking brake.
2. 1.2. Select Drive links/checks.
3. 1.3. Move to installation position.
2. Release and unclip connector for the brake pad wear indicator and remove it from the holder
-arrow- .
Fig 1: Removing Cable
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
NOTE: Removal of brake calliper
1. Paint defects on brake calliper
→ Proceed with care when setting back the brake pads.
→ Protect brake calliper from paint defects using a suitable cloth.
3. Evenly set back brake pads a little using water pump pliers.
4. Detach the brake calliper on the wheel carrier and suspend it at a suitable place in the wheel
housing or set it down carefully (do not open the brake hydraulic system!).
→ 474119 REMOVING AND INSTALLING REAR BRAKE CALLIPER
Fig 2: Removing Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Unscrew fastening screw -B- and remove brake disc.
Fig 3: Locating Brake Disc Screws
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465319 REMOVING AND INSTALLING REAR BRAKE DISC > INSTALLING REAR
BRAKE DISC
Information
Replace brake calliper fastening screws each time they are removed .
Do not confuse left and right brake discs during assembly!
1. Check that all parts are in perfect condition (visual inspection) and replace them if necessary.
2. Clean the flat and centering surfaces on the brake disc and wheel hub.
3. Apply a very thin coat of Optimoly TA to the centering surface on the wheel hub.
4. Installation is performed in reverse order.
Observe specified tightening torques:
Brake disc to wheel hub: Tightening Torque 15 Nm (11 ft. lb.)
Brake calliper to wheel bearing housing: Tightening Torque 85 Nm (63 ft. lb.)
Cable holder to wheel bearing housing: Tightening Torque 8 Nm (6 ft. lb.)
5. Position disc brake pads by operating the brake several times.
6. Check the brake fluid level and correct it if necessary.
WM 465319 REMOVING AND INSTALLING REAR BRAKE DISC > SUBSEQUENT
WORK
1. Fit wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
When replacing the brake discs and/or brake shoes, the brake shoes for the electronic parking
brake (EPB) must be ground down. The routine is initiated using the Porsche System Tester.
→ 468350 REWORKING PARKING-BRAKE SHOES
It is not necessary to grind down the brake discs if you are simply removing/installing the
brake discs.
1. Set the brake discs to the basic setting if necessary and calibrate the system . → WM
468316 ADJUSTING AND CALIBRATING BRAKE SHOES
2. Connect and start the Porsche System Tester. Follow the instructions on the Porsche System
Tester.
1. 2.1. Adjust parking-brake shoes. → 468316 ADJUSTING AND CALIBRATING
PARKING-BRAKE SHOES
2. 2.2. Rework parking-brake shoes.
→ 468350 REWORKING (GRINDING) PARKING-BRAKE SHOES
3. 2.3. Adjust and calibrate the parking-brake shoes.
→ 468316 ADJUSTING AND CALIBRATING PARKING-BRAKE SHOES
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >
INFORMATION ON CHECKING PCCB BRAKE DISCS > NOTE ON PICTURES SHOWN
Information
The pictures shown in this document may differ from the original .
cardiagn.com
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >
INFORMATION ON CHECKING PCCB BRAKE DISCS > GENERAL INFORMATION ON
PCCB BRAKE DISCS
The brake discs have wear indicator plates in the friction surfaces. The wear indicator plates (six on
each brake disc) are arranged close to the outer diameter, offset by 120 ° -arrows- at three points. The
three wear indicator plates on each friction surface (3 on the inside and 3 on the outside) are positioned
directly opposite each other. Each wear indicator is approx. 2 cm2 . The wear indicators are barely
visible on new brake discs.
Fig 1: Locating PCCB Brake Discs Wear Indicators
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
The minimum brake disc thickness (wear dimension) is stamped on the brake-disc chamber (e.g. Min.
Th. 29.7 mm).
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >
INFORMATION ON CHECKING PCCB BRAKE DISCS > BASIC INFORMATION
Checking involves the following tasks: Information
1. Visual inspection for surface changes in the brake disc friction surfaces and wear indicators.
Indication of wear: Connected surface fracture > 1 cm2-arrow- , without adding up smaller
fractures → 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) -
section on "Checking".
Fig 1: Locating Brake Disc Surface Fracture
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Check surface roughness Rk of brake discs (max. 80 μm permitted) since this affects braking
comfort (noises), braking behavior/pedal pressure and brake-pad service life → 465402
CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Checking".
Fig 2: Identifying Surface Roughness Of PCCB Brake Disc
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Check brake discs for minimum thickness -X- . The minimum thickness of the brake disc
(example: Min. Th. 29.7 mm) is stamped on the brake disc hub → 465402 CHECKING REAR
PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Checking".
Fig 3: Identifying Minimum Thickness Of PCCB Brake Disc
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Check brake discs for edge damage -arrow- (damage due to improper use) → 465402
CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Checking".
Fig 4: Identifying PCCB Brake Disc Edge Damage
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >
INFORMATION ON CHECKING PCCB BRAKE DISCS > GENERAL INFORMATION ON
REPLACING WORN PCCB BRAKE DISCS
Three criteria governing the condition of the parts can make replacement necessary depending
on the wear of PCCB brake discs:
1. Surface changes in the brake disc friction surfaces (material fatigue/wear) at an advanced
stage (indication of wear: connected friction surface damage > 1 cm2 ).
2. Surface roughness of the brake disc friction surfaces too great (roughness depends on
mileage and load).
3. Brake disc minimum thickness is not attained due to wear (material erosion due to friction).
1. In practice, all three forms of brake disc erosion usually occur.
2. Only in rare cases (as a result of long-term motor-racing brake loads/very high
temperatures on the friction surfaces), surface changes can progress so quickly that the
brake discs may need to be changed earlier than planned.
3. Brake discs that have turned blue at the brake-disc chamber and/or brake callipers that
have turned a strong brown color are clear indications of high loads over a long period of
time, e.g. on the race circuit.
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >
INFORMATION ON CHECKING PCCB BRAKE DISCS > REPLACING BRAKE DISCS
(DECISION-MAKING AID)
When replacing brake discs as a result of wear (see 465402 CHECKING REAR PCCB BRAKE DISC
(WEAR ASSESSMENT) ) both brake discs must be replaced on an axle!
Irrespective of wear, a brake disc change can be necessary on the brake disc friction surfaces due to
edge damage! In this case, only one brake disc can be replaced if the friction surface of the other PCCB
brake disc is still 'as new' → 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) -
section on "Checking".
The wear indicator plates (six on each brake disc) are arranged close to the outer diameter, offset by
120 ° -arrows- at three points. The three wear indicator plates on each friction surface (3 on the inside
and 3 on the outside) are positioned directly opposite each other. Each wear indicator is approx. 2 cm2 .
The wear indicators are barely visible on new brake discs.
cardiagn.com
Fig 1: Locating Brake Disc Wear Indicators
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
The minimum brake disc thickness (wear dimension) is stamped on the brake disc hub (example: Min.
Th. 29.7 mm).
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >
INFORMATION ON CHECKING PCCB BRAKE DISCS > CRACKS (STRESS-RELIEF
MICROSTRUCTURE) IN THE BRAKE DISC FRICTION SURFACE
Cracks in the brake disc friction surfaces must be regarded differently to cracks in grey cast-iron brake
discs. These cracks are not regarded as wear criteria for PCCB brake discs and may even be present
on new brake discs, depending on the manufacturer.
cardiagn.com
Fig 1: Identifying Cracks (Stress-Relief Microstructure) In Brake Disc Friction Surfaces
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
Due to the composition of different materials in the friction layer and support body, the friction
surfaces (even when new) are coated with an uncritical crack pattern (stress-relief microstructure).
Individual relaxation cracks sometimes run along the perforated bores .
The stress-relief microstructure results from the way in which the brake disc surface is
manufactured and does not pose a risk to safety. There is also no danger of the friction layers
flaking off from the support body, since the friction layers are almost free of internal stresses as a
result of the stress-relief microstructure .
The stress-relief microstructure is sometimes clearly visible in new brake discs and the brake disc
chamber side and the side that is opposite to the chamber can differ significantly from one another
.
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >
INFORMATION ON CHECKING PCCB BRAKE DISCS > INFORMATION CONCERNING
BORES (PERFORATIONS) IN THE BRAKE DISC FRICTION SURFACE
Observe the following warning when cleaning or exposing the bores in the brake disc friction surface!
Fig 1: Identifying Bores (Perforations) In Brake Disc Friction Surface
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
NOTE: Work cannot be carried out on the bores in the brake disc friction surface
Damage to brake discs
→ Clean the bores on PCCB brake discs with high-pressure cleaning equipment if necessary. Observe
the relevant environmental and safety regulations.
→ Do not machine the bores. Drilling or counter-sinking is not permitted.
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >
INFORMATION ON CHECKING PCCB BRAKE DISCS > COATING ON THE PCCB
BRAKE DISCS (POSSIBLE CAUSES)
The coating on the PCCB brake discs arises as a result of a high load and high temperatures, for
example on a racing circuit. Check the following in such cases:
Fig 1: Identifying Coating On The PCCB Brake Discs
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Ventilation (brake cooling): All components are present, secured correctly and undamaged.
Brake pad quality: If the vehicle is used for race-track driving, use appropriate brake pads.
The perforation bores → Bores (perforations) in brake disc friction surface in the brake discs must
not be blocked.
Unblock them if necessary. → 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT)
- section on "Information".
In the event of brake pad wear, the brake discs can still be used provided the brake discs satisfy all
wear criteria → 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) - section
on "Information". The perforation bores → Bores (perforations) in brake disc friction surface must
not be blocked.
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >
INFORMATION ON CHECKING PCCB BRAKE DISCS > INFORMATION ON BEDDING
IN NEW BRAKE PADS
New brake pads require a slightly longer bedding-in period for PCCB brake discs than cast iron brake
cardiagn.com
discs.
In general, the following applies: New brake pads must be broken in (bedding-in period), their optimum
braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking
effect must be compensated for by increased pressure on the brake pedal. The same also applies after
a brake disc change.
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) > VISUAL INSPECTION
OF THE SURFACES OF THE BRAKE DISC FRICTION SURFACES (INDICATION OF
WEAR)
Information
The friction surface changes occur due to material fatigue as a result of extremely high thermal
load. These disc temperatures, which occur above all in racing conditions, cause a progressive
material fatigue .
Effects on driving: The surface change worsens the smoothness of braking, decreases the disc
strength and increases the brake pad wear and therefore makes a precautionary parts
replacement necessary .
The following illustrations (PCCB brake disc wear appearance) are to be used for damage assessment.
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) > PCCB BRAKE DISC
WEAR APPEARANCE
1. Friction surfaces after normal brake load while driving on roads. No surface fractures present -
No replacement necessary!
Fig 1: Identifying PCCB Brake Disc Wear Appearance
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Friction surfaces after a long run and occasional higher load. Isolated cases of connected
surface fractures less than 1 cm2-arrow- .
No replacement necessary as the associated surface fractures are < 1 cm2 !
Fig 2: Locating PCCB Surface Fractures
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. End of service life of friction surface or after highest load on a racing circuit.
Replace brake discs if the connected friction surface damage is > 1 cm2-arrow- . To do this,
follow the instructions → 465402 CHECKING REAR PCCB BRAKE DISC (WEAR
ASSESSMENT) - section on "Information".
Fig 3: Identifying Connected Friction Surface Damage
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
The best way to detect a surface fracture is by checking the wear indicators. Based on the
wear indicators, this means that at least one wear indicator -arrow- must have a surface
fracture of > 50% (damage > 1 cm2 /entire surface of a wear indicator with a surface area of
approx. 2 cm2 ).
Fig 4: Locating PCCB Surface Fracture On Wear Indicator
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) > EVALUATION OF
SURFACE ROUGHNESS RK (MAX. 80 MICROMETERS PERMITTED)
Information
An increase in surface roughness impairs smoothness of braking (rubbing, shaking in steering
wheel, scraping noises) and increases brake pad wear .
With a roughness (Sr) value of > 80 μm (> 80 micrometer), a precautionary parts replacement is
required .
The assessment is carried out visually, based on the diagram. Two illustrations of the same peak-to
valley surface roughness (views 1 and 2) help to make a better assessment.
1. Brake discs that are OK:
1. 1.1. Surface roughness (Rk) = 6 μm -see illustration- (view 1)Fig 1
Fig 1: Locating PCCB Surface Roughness 6 Micrometers (View 1)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Surface roughness (Rk) = 6 μm -see illustration- (view 2)Fig 2
New brake disc. Illustration is used for better classification.
The early stages of roughness are indicated by burnt-out carbon fibres on the
surface of an otherwise intact, semi-matt surface.
The surface feels smooth.
Fig 2: Locating PCCB Surface Roughness 6 Micrometers (View 2)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 1.2. Surface roughness (Rk) = 56 μm -see illustration- (view 1)Fig 3
Fig 3: Locating PCCB Surface Roughness 56 Micrometers (View 1)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Surface roughness (Rk) = 56 μm -see illustration- (view 2)Fig 4
In the advanced stages of fibre burnout and the initial destruction of the Si and SiC
'matrix', the depressions have become more pronounced. Large sections of the
surface are still intact, the depressions form an even, fine-grained pattern.
The surface still feels matt, however, and the roughness is not yet pronounced.
No replacement necessary!
Fig 4: Locating PCCB Surface Roughness 56 Micrometers (View 2)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 1.3. Surface roughness (Rk) = 72 μm -see illustration- (view 1)Fig 5
Fig 5: Locating PCCB Surface Roughness 72 Micrometers (View 1)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Surface roughness (Rk) = 72 μm -see illustration- (view 2)Fig 6
Borderline disc, which can still just be evaluated as OK. As a result of more
advanced damage to the surface, the depressions are larger, and above all deeper,
compared with the previous surface condition.
On the one hand, the more extensive roughness is noticeable (only when a
comparison is made); on the other hand, however, like before, "only" depressions are
observed.
Replacement not yet necessary!
Fig 6: Locating PCCB Surface Roughness 72 Micrometers (View 2)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Worn brake discs:
1. 2.1. Surface roughness (Rk) = 108 μm -see illustration- (view 1)Fig 7
Fig 7: Locating PCCB Surface Roughness 108 Micrometers (View 1)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Surface roughness (Rk) = 108 μm -see illustration- (view 2)Fig 8
Worn surface. Advanced wear has led to a situation where only the remains of the
original surface are left.
It is clear that the roughness is caused not only by depressions but also by bumps.
Replace brake discs! To do this, follow the instructions → 465402 CHECKING REAR
PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Information".
In general, the following applies: Brake discs must be replaced if the surface
roughness (Rk) is > 80 μm!
Fig 8: Locating PCCB Surface Roughness 108 Micrometers (View 2)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Worn Brake Discs (Special Cases):
1. 3.1. Surface roughness Rk = 108 μm, as for previous disc, but with some of the
original friction surface remaining -arrow- .
Replace brake discs! To do this, follow the instructions → 465402 CHECKING REAR
PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Information".
In general, the following applies: Brake discs must be replaced if the surface
roughness (Rk) is > 80 μm!
Fig 9: Identifying Worn Brake Disc
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Surface roughness (Rk) = 72 μm. Borderline disc, identified by the roughness,
but also by the indication of wear and connected surface fractures -arrows- , > 1
cm2 .
Replace brake discs! To do this, follow the instructions → 465402 CHECKING REAR
PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Information".
Fig 10: Identifying PCCB Brake Disc Surface Roughness
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) > CHECKING MINIMUM
THICKNESS OF BRAKE DISCS
Information
For perforated brake discs, the minimum thickness -X- must always be measured on the inner or
outer friction surface track -arrows- .
Fig 1: Identifying Minimum Thickness Of PCCB Brake Disc
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Wear limit: The minimum brake disc thickness is stamped on the brake-disc chamber (e.g. Min. Th.
29.7 mm) .
Measure the brake disc thickness -X- using a suitable micrometer screw or brake disc gauge
around the inner or outer friction surface tracks -arrows- .
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) > CHECKING BRAKE
DISCS FOR EDGE DAMAGE
Information
Irrespective of wear, a brake disc change can be necessary on the brake disc friction surfaces due
to edge damage .
In such cases, only one brake disc may need to be replaced if the friction area surface of the other
PCCB brake disc is still completely OK .
The following criteria apply to edge damage assessment:
Fig 1: Identifying PCCB Brake Disc Edge Damage
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Max. permissible width/depth = 2 mm (0.08 inches)
Max. permitted length = 10 mm (0.39 inches)
Max. 3 damaged edge areas permissible
WM 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) > TOOLS
Designation Type Number Description
PIWIS Tester II Special Tool 9818
WM 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) > TECHNICAL
VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
No. 7: Fastening M12 x 1.5 thread Tightening 15 Nm (11 ft.
cardiagn.com
screw securing (always replace Torque lb.)
brake disc to screws and lock
wheel hub nuts after
removal)
No. 10: ABS M6 x 12 thread Tightening 8 Nm (6 ft. lb.)
cable holder to Torque
rear-axle wheel
carrier
Threaded M12 x 1.5 x 115 Tightening 85 Nm (63 ft.
connection thread (always Torque lb.)
securing brake replace screws
calliper to and lock nuts
rear-axle wheel after removal)
carrier
WM 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) >
PRELIMINARY WORK
1. Raise the vehicle → 4X00IN LIFTING THE VEHICLE .
2. Remove wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND
INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) > REMOVING
REAR BRAKE DISC (PCCB) > REMOVING AND INSTALLING REAR BRAKE DISC
(PCCB)
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
1. PIWIS Tester II 9818 must be connected and started.
1. 1.1. Select parking brake.
2. 1.2. Select Maintenance/repair.
3. 1.3. Move to installation position.
2. Release and unclip connector for the brake pad wear indicator and remove it from the holder
-arrow- .
Fig 1: Removing Cable
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
NOTE: Removal of brake calliper
1. Paint defects on brake calliper
→ Proceed with care when setting back the brake pads.
→ Protect brake calliper from paint defects using a suitable cloth.
3. Set the brake pads back slightly and evenly using water pump pliers.
4. Detach the brake calliper on the wheel carrier and suspend it at a suitable place in the wheel
housing or set it down carefully (do not open the brake hydraulic system!).
→ 474119 REMOVING AND INSTALLING REAR BRAKE CALLIPER (PCCB)
Fig 2: Removing Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Unscrew fastening screw -B- and remove brake disc.
Fig 3: Locating Brake Disc Fastening Screws
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) >
EXPLANATION OF TWO-PART BRAKE DISC
The PCCB brake discs consist of two parts on the front and rear axles. The brake disc -1- is
screwed to the brake disc hub -2- with 10 screws (M6) -3- .
Only the complete brake disc is available as a spare part (disc + brake disc hub)!
Do not separate the brake disc hub -2- and brake disc -1- .
Do not attempt to turn the screws -3- . The screws are prevented from turning by compression in
the bush.
Changing the Tightening Torque of the screws -3- will have negative effects on the noise
produced.
Fig 1: Identifying Two-Part Brake Disc
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) > INSTALLING
REAR BRAKE DISC > INSTALLING REAR BRAKE DISC (PCCB)
Information
Replace brake calliper fastening screws each time they are removed .
Do not confuse right and left brake discs during assembly!
1. Check that all parts are in perfect condition (visual inspection) and replace them if necessary.
2. Clean the levelling and centering surfaces on the brake disc and wheel hub.
3. Apply a very thin coat of Optimoly TA to the centering surface on the wheel hub.
4. Installation is performed in reverse order
Observe specified tightening torques:
Brake disc to wheel hub: Tightening Torque 15 Nm (11 ft. lb.)
Brake calliper to wheel bearing housing: Tightening Torque 85 Nm (63 ft. lb.)
Cable holder to wheel bearing housing: Tightening Torque 8 Nm (6 ft. lb.)
5. Connect and start the Porsche System Tester.
1. 5.1. Adjust and calibrate the parking-brake shoes.
→ 468316 ADJUSTING AND CALIBRATING PARKING-BRAKE SHOES
6. Position disc brake pads by operating the brake several times.
7. Check the brake fluid level and correct it if necessary.
WM 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) >
SUBSEQUENT WORK
1. Fit wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) >
SUBSEQUENT WORK > INFORMATION ON BEDDING IN NEW BRAKE PADS
New brake pads require a slightly longer bedding-in period for PCCB brake discs than cast iron brake
discs.
In general, the following applies: New brake pads must be worn in (bedding-in period). Their optimum
braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking
effect must be compensated for by increased pressure on the brake pedal. The same also applies after
changing brake discs.
WM 465419 REMOVING AND INSTALLING REAR PCCB BRAKE DISC > TOOLS
Designation Type Number Description
PIWIS Tester II Special Tool 9818
cardiagn.com
WM 465419 REMOVING AND INSTALLING REAR PCCB BRAKE DISC >
INFORMATION > NOTE ON PICTURES SHOWN
The pictures shown in this document may differ from the original .
WM 465419 REMOVING AND INSTALLING REAR PCCB BRAKE DISC > PRELIMINARY
WORK
1. Raise the vehicle → 4X00IN LIFTING THE VEHICLE .
2. Remove wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND
INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465419 REMOVING AND INSTALLING REAR PCCB BRAKE DISC > REMOVING
REAR PCCB BRAKE DISC > REMOVING AND INSTALLING REAR BRAKE DISC
(PCCB)
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
1. PIWIS Tester II 9818 must be connected and started.
1. 1.1. Select parking brake.
2. 1.2. Select Maintenance/repair.
3. 1.3. Move to installation position.
2. Release and unclip connector for the brake pad wear indicator and remove it from the holder
-arrow- .
Fig 1: Removing Cable
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
NOTE: Removal of brake calliper
1. Paint defects on brake calliper
→ Proceed with care when setting back the brake pads.
→ Protect brake calliper from paint defects using a suitable cloth.
3. Set the brake pads back slightly and evenly using water pump pliers.
4. Detach the brake calliper on the wheel carrier and suspend it at a suitable place in the wheel
housing or set it down carefully (do not open the brake hydraulic system!).
→ 474119 REMOVING AND INSTALLING REAR BRAKE CALLIPER (PCCB)
Fig 2: Removing Brake Calliper
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Unscrew fastening screw -B- and remove brake disc.
Fig 3: Locating Brake Disc Fastening Screw
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465419 REMOVING AND INSTALLING REAR PCCB BRAKE DISC >
EXPLANATION OF TWO-PART BRAKE DISC
1. The PCCB brake discs consist of two parts on the front and rear axles. The brake disc -1- is
screwed to the brake-disc chamber -2- with screws (M6) -3- .
Fig 1: Identifying PCCB Brake Discs
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fig 2: Identifying Two-Part Brake Disc
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Only the complete brake disc is available as a spare part (disc + brake-disc chamber)!
3. Do not separate the brake-disc chamber -2- and brake disc -1- . In addition, the screws -3-
must not be turned and should not need to be turned. The screws are prevented from turning
by compression in the bushing.
4. It is essential that the Tightening Torque of the screws is not changed (do not turn the screws)
as this can have a negative effect on the sound behavior.
1 Brake disc
2 Brake-disc chamber
3 Screw
WM 465419 REMOVING AND INSTALLING REAR PCCB BRAKE DISC > INSTALLING
REAR BRAKE DISC > INSTALLING REAR BRAKE DISC (PCCB)
Information
Replace brake calliper fastening screws each time they are removed .
Do not confuse right and left brake discs during assembly!
1. Check that all parts are in perfect condition (visual inspection) and replace them if necessary.
2. Clean the levelling and centering surfaces on the brake disc and wheel hub.
3. Apply a very thin coat of Optimoly TA to the centering surface on the wheel hub.
4. Installation is performed in reverse order
Observe specified tightening torques:
Brake disc to wheel hub:
Brake calliper to wheel bearing housing:
Cable holder to wheel bearing housing:
5. Connect and start the Porsche System Tester.
1. 5.1. Adjust and calibrate the parking-brake shoes.
cardiagn.com
→ 468316 ADJUSTING AND CALIBRATING PARKING-BRAKE SHOES
6. Position disc brake pads by operating the brake several times.
7. Check the brake fluid level and correct it if necessary.
WM 465419 REMOVING AND INSTALLING REAR PCCB BRAKE DISC >
SUBSEQUENT WORK
1. Fit the wheel. Use assembly aids (Assembly Pins) -1- . → 44051900 REMOVING AND
INSTALLING WHEEL
Fig 1: Identifying Assembly Aids (Assembly Pins)
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 465419 REMOVING AND INSTALLING REAR PCCB BRAKE DISC >
SUBSEQUENT WORK > INFORMATION ON BEDDING IN NEW BRAKE PADS
New brake pads require a slightly longer bedding-in period for PCCB brake discs than cast iron brake
discs.
In general, the following applies: New brake pads must be worn in (bedding-in period). Their optimum
braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking
effect must be compensated for by increased pressure on the brake pedal. The same also applies after
changing brake discs.
WM 466119 REMOVING AND INSTALLING ACTUATOR FOR ELECTRIC PARKING
BRAKE > TECHNICAL VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
Actuator For Tightening 2 Nm (1.5 ft.
Parking Brake Torque lb.)
WM 466119 REMOVING AND INSTALLING ACTUATOR FOR ELECTRIC PARKING
BRAKE > PRELIMINARY WORK
Remove trim panel under dashboard. → REMOVING TRIM PANEL UNDER DASHBOARD - section on
"Removing"
WM 466119 REMOVING AND INSTALLING ACTUATOR FOR ELECTRIC PARKING
BRAKE > REMOVING ACTUATOR FOR ELECTRIC PARKING BRAKE
Fig 1: Identifying Electric Parking Brake Actuator Installation Position
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Unscrew and remove two fastening screws -2- and remove actuator for electric parking brake
-1- .
Fig 2: Identifying Actuator For Electric Parking Brake
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 466119 REMOVING AND INSTALLING ACTUATOR FOR ELECTRIC PARKING
BRAKE > INSTALLING ACTUATOR FOR ELECTRIC PARKING BRAKE
1. Fit actuator for electric parking brake -1- and tighten two fastening screws -2- to →
Tightening Torque: 2 Nm (1.5 ft. lb.) .
Fig 1: Identifying Actuator For Electric Parking Brake
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Carry out a function test.
1. The indicator light in the parking brake actuator must be ON when you close it.
2. The indicator light in the parking brake actuator must be OFF when you open it.
3. Check for locking and release noises from the electric parking brake actuators when you
actuate them.
WM 466119 REMOVING AND INSTALLING ACTUATOR FOR ELECTRIC PARKING
BRAKE > SUBSEQUENT WORK
Install trim panel under dashboard. → INSTALLING TRIM PANEL UNDER DASHBOARD - section on
"Installing"
WM 466119 REMOVING AND INSTALLING ACTUATOR FOR ELECTRIC PARKING
BRAKE (EPB) > TECHNICAL VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
Actuator For Tightening 2 Nm (1.5 ft.
Parking Brake Torque lb.)
WM 466119 REMOVING AND INSTALLING ACTUATOR FOR ELECTRIC PARKING
BRAKE (EPB) > PRELIMINARY WORK
Remove trim panel under dashboard. → REMOVING TRIM PANEL UNDER DASHBOARD - section on
"Removing"
WM 466119 REMOVING AND INSTALLING ACTUATOR FOR ELECTRIC PARKING
BRAKE (EPB) > REMOVING ACTUATOR FOR ELECTRIC PARKING BRAKE
Fig 1: Identifying Electric Parking Brake Actuator Installation Position
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Unscrew two fastening screws -2- and remove actuator for electric parking brake -1- .
Fig 2: Identifying Electric Parking Brake Actuator Fastening Screws
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 466119 REMOVING AND INSTALLING ACTUATOR FOR ELECTRIC PARKING
BRAKE (EPB) > INSTALLING ACTUATOR FOR ELECTRIC PARKING BRAKE
1. Fit actuator for electric parking brake -1- and tighten two fastening screws -2- to →
Tightening Torque: 2 Nm (1.5 ft. lb.) .
Fig 1: Identifying Installing Actuator For Electric Parking Brake
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Perform a function test.
1. The indicator light in the parking brake actuator must be ON when you close it.
2. The indicator light in the parking brake actuator must be OFF when you open it.
3. Check for locking and release noises from the electric parking brake actuators when you
actuate them.
WM 466119 REMOVING AND INSTALLING ACTUATOR FOR ELECTRIC PARKING
BRAKE (EPB) > SUBSEQUENT WORK
Install trim panel under dashboard. → INSTALLING TRIM PANEL UNDER DASHBOARD - section on
"Installing"
WM 466219 REMOVING AND INSTALLING CONTROL UNIT FOR ELECTRIC PARKING
BRAKE > TOOLS
Designation Type Number Description
PIWIS Tester II Special Tool 9818
WM 466219 REMOVING AND INSTALLING CONTROL UNIT FOR ELECTRIC PARKING
BRAKE > PRELIMINARY WORK
1. If the control unit for the electric parking brake has to be replaced, the values must be read out
before removal using PIWIS Tester II 9818 . → 466255 REPLACING CONTROL UNIT FOR
ELECTRIC PARKING BRAKE .
cardiagn.com
2. Remove side trim panel for rear luggage compartment at the right. → REMOVING SIDE TRIM
PANEL FOR REAR LUGGAGE COMPARTMENT - section on "Removing"
WM 466219 REMOVING AND INSTALLING CONTROL UNIT FOR ELECTRIC PARKING
BRAKE > REMOVING AND INSTALLING CONTROL UNIT FOR ELECTRIC PARKING
BRAKE > REMOVING CONTROL UNIT FOR ELECTRIC PARKING BRAKE
Fig 1: Identifying Installation Position Of Control Unit For Electric Parking Brake
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
Always comply with the regulations for handling ESD-sensitive components!
Assembly work may only be carried out if the mechanic is wearing the working clothes and shoes
approved by Porsche .
The new part must only be removed from the ESD (electrostatic discharge) protective packaging
just before installation and at the position at which the part is to be installed .
Never touch the electric pins and plug contacts .
NOTE: Voltage peaks
Risk of damage to load or to the control unit
→ Remove the ignition key and switch off load before disconnecting or removing load.
1. Unscrew the two fastening screws -1- .
cardiagn.com
Fig 2: Identifying Control Unit For Electric Parking Brake
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Release plug connection -1- and disconnect it -2- .
Fig 3: Disconnecting Plug Connection
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 466219 REMOVING AND INSTALLING CONTROL UNIT FOR ELECTRIC PARKING
BRAKE > REMOVING AND INSTALLING CONTROL UNIT FOR ELECTRIC PARKING
BRAKE > INSTALLING CONTROL UNIT FOR ELECTRIC PARKING BRAKE
1. Connect plug connection -2- and lock it -1- .
Fig 1: Connecting Control Unit For Electric Parking Brake Plug Connection
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Place control unit for electric parking brake in installation position.
3. Secure the control unit with the two fastening screws -1- .
Fig 2: Identifying Control Unit For Electric Parking Brake Screws
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 466219 REMOVING AND INSTALLING CONTROL UNIT FOR ELECTRIC PARKING
BRAKE > SUBSEQUENT WORK
1. If the control unit for the electric parking brake was replaced, the values must be written using
PIWIS Tester II 9818 . Replace control unit for electric parking brake. → 466255 REPLACING
CONTROL UNIT FOR ELECTRIC PARKING BRAKE .
2. Remove side trim panel for rear luggage compartment at the right. → INSTALLING SIDE TRIM
PANEL FOR REAR LUGGAGE COMPARTMENT - section on "Installing"
WM 466255 REPLACING CONTROL UNIT FOR ELECTRIC PARKING BRAKE > TOOLS
Designation Type Number Description
PIWIS Tester II Special Tool 9818
WM 466255 REPLACING CONTROL UNIT FOR ELECTRIC PARKING BRAKE >
TECHNICAL VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
Current Rating Nominal value 40 A
cardiagn.com
WM 466255 REPLACING CONTROL UNIT FOR ELECTRIC PARKING BRAKE >
CODING AND CALIBRATING CONTROL UNIT
NOTE: Voltage drop
Risk of irreparable damage to control unit
Risk of damage to control unit
Fault entries in the control unit
Coding in the control unit is aborted
Malfunctions in control unit, even during programming
→ Prior to disconnecting the control unit, switch off ignition and remove ignition key.
→ Ensure that the power supply is not interrupted during programming.
→ Connect a battery charger with a current rating of at least → Nominal value: 40 A to the vehicle
battery.
Information
The PIWIS Tester II 9818 instructions take precedence since the description may be different with later
Tester releases.
The procedure described here has been structured in general terms. Different text or additional
information may appear in PIWIS Tester II 9818 .
1. Switch off ignition and replace control unit. → 466219 REMOVING AND INSTALLING
CONTROL UNIT FOR ELECTRIC PARKING BRAKE .
2. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on
ignition.
3. Select the vehicle type and start the diagnostic application.
4. Select Parking brake in the control unit overview .
5. Codings/adaptations must now be selected.
6. Automatic coding must then be selected. Press [F12] to start coding.
7. The Tester displays the message Coding has been completed successfully . Press [F12] to
continue.
8. Drive links/checks must be selected.
9. Move to installation position and press [F12] to continue.
10. Press [F8] to start the function and follow the instructions on the Tester.
11. Select Check parking brake basic setting in the Maintenance/repairs menu and press
[F12] to continue.
cardiagn.com
12. Follow the instructions on the Tester and press [F12] to continue.
13. Complete the following steps on vehicles with steel brakes. Do not perform the Bedding in
function on vehicles with PCCB.
1. 13.1. Select the Bedding in function, then press [F12].
2. 13.2. Follow the instructions on the Tester and press [F8] to start the function.
3. 13.3. Follow the instructions on the Tester.
14. Select Calibrate parking brake distance sensor function and press [F12] to continue.
1. 14.1. Follow the instructions on the Tester and press [F12] to continue.
2. 14.2. Start the calibration process by pressing [F8].
3. 14.3. Follow the instructions on the Tester.
15. Read out the fault memory and erase it if necessary. Return to the overview of all control
units.
16. Check electric parking brake operation by pressing the parking brake operating button. The
LED in the button may flash after the first function test.
1. 16.1. If the LED in the button starts flashing after the first function test:
1. 16.1.1. Perform a further function test. Check electric parking brake
operation by actuating the lever.
17. Perform a test drive, check the function of the electric parking brake by actuating the lever and
read out the fault memory.
WM 468316 ADJUSTING AND CALIBRATING BRAKE SHOES > TECHNICAL VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
Actual Displayed on the Control value 000 mm
dimension Tester! Actual
gap dimension at
left and right
measured
between the
shoe and drum in
millimetres.
Required Displayed on the Control value +2.2 mm +/-0.3 mm
dimension Tester! Required
dimension
between the
shoe and drum in
millimetres.
Adjustment Must be Control value 000 mm
dimension calculated! Value
cardiagn.com
(in millimetres)
by which the
adjustment
device must be
turned.
Adjustment 1 click Control value 0.15 mm
device corresponds to
WM 468316 ADJUSTING AND CALIBRATING BRAKE SHOES > ADJUSTING AND
CALIBRATING PARKING-BRAKE SHOES
Information
The electric parking brake with asbestos-free brake pads must never be adjusted in such a way
that the pad has to grind free during operation . → 468350 GRINDING DOWN PARKING-BRAKE
SHOES
Adjustments must only be carried out at the two rear wheel adjustment devices .
Make sure that the EPB cables are routed and guided correctly .
In the event of unfavorable tolerances, the brake pads may prevent the brake disc from turning freely. If
this happens, the brake pads must be pressed back slightly and uniformly using water pump pliers.
1. Raise the vehicle. → 4X00IN LIFTING THE VEHICLE
2. Remove rear wheels. → 440519 REMOVING AND INSTALLING WHEEL
3. Release the EPB so that the brake discs can turn freely.
4. Move the brake shoes into installation position using the Porsche System Tester. Select
>>Parking brake<< in the control unit overview. Select >>Drive links/checks>>All<< >>Move to
installation position<<.
5. Adjust brake shoes on both sides. To do this, turn the relevant brake disc with the opening to
the adjustment device position. Using a screwdriver, adjust the adjustment device until the
brake disc can no longer be turned. The subsequent torque of the brake disc must be greater
than 100 Nm (74 ft. lb.). Then loosen 17 (+/- 1) clicks of the adjustment device (brake discs
must be able to turn freely).
6. Using the Porsche System Tester, select >>Parking brake<< in the control unit overview.
Select >>Maintenance/repairs<< >>Check parking brake basic setting<<.
It may be necessary to fine-tune the adjustment device after selecting >>Check parking brake
basic setting<<.
Location Description Type Basic value Tolerance 1 Tolerance 2
Actual Displayed on Control value 000 mm
dimension the Tester!
Actual gap
dimension at
left and right
measured
cardiagn.com
between the
shoe and drum
in millimetres.
Required Displayed on Control value +2.2 mm +/-0.3 mm
dimension the Tester!
Required
dimension
between the
shoe and drum
in millimetres.
Adjustment Must be Control value 000 mm
dimension calculated!
Value (in
millimetres) by
which the
adjustment
device must be
turned.
Adjustment dimension = required dimension - actual dimension (required dimension
minus actual dimension)
Fig 1: Calibrating Parking-Brake Shoes
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
cardiagn.com
Fig 2: Adjusting Parking-Brake Shoes
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
cardiagn.com
→ Control value: 0.15 mm
Corresponds to 1 click on the adjustment device
Information
A calculated value in the positive range means: Turn adjustment device towards A - loosen.
A calculated value in the negative range means: Turn adjustment device towards B - tighten.
Adjustment dimension = required dimension - actual dimension (required dimension
minus actual dimension)
Example:
Actual dimension: 2.6 mm
Required dimension: 2.0 mm (+/- 0.3 mm)
Adjustment dimension = required dimension - actual dimension
Adjustment dimension = 2.0 mm - 2.6 mm
Adjustment dimension = -0.6 mm
-0.6 mm: 0.15 mm = - 4 clicks (0.15 mm corresponds to one click!)
Adjustment dimension = -0.6 mm: This means that the gap dimension is too big and the
adjustment device must be adjusted towards B - tighten.
cardiagn.com
7. Grind parking-brake shoes (not PCCB!) → 468350 REWORKING (GRINDING)
PARKING-BRAKE SHOES .
8. Calibrate the EPB using the Porsche System Tester. To do this, select >>Parking brake<< in
the control unit overview. Select >>Maintenance/repairs<< >>Calibration<<.
9. To check the function of the EPB, actuate the EPB button several times (press 2-3 times) and
make sure that the actuators open and close on both sides.
Position disc brake pads by operating the brake several times.
10. Fit wheels → INSTALLING WHEEL - section on "Installing".
WM 468350 REWORKING (GRINDING) BRAKE SHOES > REWORKING (GRINDING)
PARKING-BRAKE SHOES
Information
Grinding applies only to vehicles with steel brakes. PCCB brake discs/brake shoes do not need to be
ground down.
Grinding must be performed after setting the brake shoes to the basic setting.
The brake shoes must be ground down prior to calibration.
It is not necessary to grind down the brake shoes if you are simply removing/installing the brake discs
→ 465319 REMOVING AND INSTALLING REAR BRAKE DISC , → 468356 REPLACING BRAKE
SHOES .
NOTE: Each time the brake discs and/or brake shoes are replaced, the electric parking
brake (EPB) must be ground down after first setting the brake shoes to the basic setting →
468316 SETTING AND CALIBRATING PARKING-BRAKE SHOES . The electric parking
brake will only function fully after it has been ground down and calibrated. This involves
driving the vehicle eight times from standstill to 10 km/h (6 mph) up to max. 20 km/h (12 mph)
for a distance of 20 meters. If the distance in meters is not sufficient for several consecutive
cycles, you can perform a reset with the vehicle after every cycle and drive on the same
stretch of road several times!
The >>Grind brake shoes<< routine is initiated using the Porsche System Tester.
1. Select >>Parking brake<< in the control unit overview. Select >>Maintenance/repairs<<
>>Grinding<<. Follow the instructions on the Porsche System Tester.
2. Once the brake shoes have been ground down correctly, the EPB must be calibrated. →
468316 ADJUSTING PARKING-BRAKE SHOES
WM 468350 GRINDING DOWN PARKING-BRAKE SHOES (EPB) > REWORKING
(GRINDING) PARKING-BRAKE SHOES
Information
Grinding applies only to vehicles with steel brakes. PCCB brake discs/brake shoes do not need to be
ground down.
cardiagn.com
Grinding must be performed after setting the brake shoes to the basic setting.
The brake shoes must be ground down prior to calibration.
It is not necessary to grind down the brake shoes if you are simply removing/installing the brake discs
→ 465319 REMOVING AND INSTALLING REAR BRAKE DISC , → 468356 REPLACING BRAKE
SHOES .
NOTE: Each time the brake discs and/or brake shoes are replaced, the electric parking
brake (EPB) must be ground down after first setting the brake shoes to the basic setting →
468316 SETTING AND CALIBRATING PARKING-BRAKE SHOES . The electric parking
brake will only function fully after it has been ground down and calibrated. This involves
driving the vehicle eight times from standstill to 10 km/h (6 mph) up to max. 20 km/h (12 mph)
for a distance of 20 meters. If the distance in meters is not sufficient for several consecutive
cycles, you can perform a reset with the vehicle after every cycle and drive on the same
stretch of road several times!
The >>Grind brake shoes<< routine is initiated using the Porsche System Tester.
1. Select >>Parking brake<< in the control unit overview. Select >>Maintenance/repairs<<
>>Grinding<<. Follow the instructions on the Porsche System Tester.
2. Once the brake shoes have been ground down correctly, the EPB must be calibrated. →
468316 ADJUSTING PARKING-BRAKE SHOES
WM 468356 REPLACING BRAKE SHOES > PRELIMINARY WORK
1. Raise the vehicle. → 4X00IN LIFTING THE VEHICLE
2. Remove wheel. → 440519 REMOVING AND INSTALLING WHEEL
3. Remove brake disc. → 465319 REMOVING AND INSTALLING REAR BRAKE DISC
WM 468356 REPLACING BRAKE SHOES > INFORMATION > NOTE ON PICTURES
SHOWN
The pictures shown in this document may differ from the original .
WM 468356 REPLACING BRAKE SHOES > REMOVING BRAKE SHOES
Information
It is not necessary to grind down the parking-brake shoes if the parking-brake shoes are not replaced.
Set the brake shoes to the basic setting if necessary and calibrate the brakes → WM 468316
ADJUSTING AND CALIBRATING BRAKE SHOES .
Mark the parking-brake shoes and adjustment device according to their installation position .
Secure the adjustment device to prevent it from turning .
1. Brake Shoes
2. Adjustment Device
cardiagn.com
3. Compression Springs
4. Tension Springs
Fig 1: Component Overview Of Parking Brake
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Loosen adjustment device -2- with a screwdriver. → Adjustment device
Fig 2: Identifying Adjustment Device
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WARNING: Preloaded or pressurized components
1. Risk of injury (e.g. crushing or bruising) when removing and installing springs.
→ Do not reach into the danger area.
→ Relieve the tension on components before starting work.
→ Secure components to prevent them from loosening suddenly.
→ Wear protective gloves and goggles.
→ Be very careful when working on the brake system.
2. Remove compression springs -3- . → Compression springs
Fig 3: Compressing Brake System Springs
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Disengage both tension springs -4- . → Tension springs
Fig 4: Locating Brake System Tension Springs
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Remove brake shoes with adjustment device -1 and 2- .
5. Secure actuator for parking brake with a tie-wrap -arrow- .
Fig 5: Securing Actuator For Parking Brake With Tie-Wrap
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 468356 REPLACING BRAKE SHOES > INSTALLING BRAKE SHOES
1. Brake Shoes
2. Adjustment Device
3. Compression Springs
4. Tension Springs
Fig 1: Component Overview Of Parking Brake
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Installation is performed in reverse order.
Align the entire unit in the middle.
1. Remove tie-wrap at actuator for parking brake.
2. Insert brake shoes with adjustment device -1 and 2- .
WARNING: Preloaded or pressurized components
1. Risk of injury (e.g. crushing or bruising) when removing and installing springs.
→ Do not reach into the danger area.
→ Relieve the tension on components before starting work.
→ Secure components to prevent them from loosening suddenly.
→ Wear protective gloves and goggles.
→ Be very careful when working on the brake system.
3. Engage both tension springs -4- .
4. Install compression springs -3- and plug in speed sensor connector again.
WM 468356 REPLACING BRAKE SHOES > SUBSEQUENT WORK
1. Install brake disc. → 465319 REMOVING AND INSTALLING REAR BRAKE DISC
2. Adjust and calibrate the brake shoes. → WM 468316 ADJUSTING AND CALIBRATING
BRAKE SHOES
Always grind down the brake shoes during adjustment and calibration.
3. Fit wheel. → 440519 REMOVING AND INSTALLING WHEEL
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE > TECHNICAL
VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
No. 1: Actuator Tightening 20 Nm (15 ft. +60° (+44 ft. lb.)
cardiagn.com
to wheel carrier Torque lb.)
No. 6: Brake M6 x 12 thread Tightening 8 Nm (6 ft. lb.)
carrier to rear Torque
wheel carrier
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE > PRELIMINARY
WORK
1. Remove wheel. → REMOVING WHEEL - section on "Removing"
2. Move electric parking brake (EPB) into >>installation position<< using the Porsche System
Tester. To do this, select >>Parking brake<< in the control unit overview. Select >>Drive
links/checks<< >>All<< >>Move to installation position<<.
3. Remove brake calliper and hang it at a suitable place in the wheel arch. → REMOVING REAR
BRAKE CALLIPER - section on "Removing"
4. Remove brake disc. → 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) -
section on "Removing"
5. Remove brake shoes. → 468356 REPLACING BRAKE SHOES - section on "Removing"
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE > REMOVING
SPREADER DEVICE (EPB) > REMOVING SPREADER DEVICE FOR EPB
Information
The pictures shown in this document may differ from the original .
The spreader device (actuator) is located on the rear-axle wheel bearing housing instead of the
mechanical spreader device with the parking-brake cable.
1. Actuator
2. Tie-wrap - prevents twisting
Fig 1: Identifying EPB Actuator
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Release electric plug connection -2- at the actuator -1- (-a- ) and pull it off -A- .
Fig 2: Removing Plug Connection For Actuator
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Unclip wire harness -4- from the retaining clip -3- .
3. If the actuator has to be re-used, secure it in the brake shoe mountings with a tie-wrap to
prevent it from twisting! -arrow-
Fig 3: Identifying Servo Motor Lock
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Loosen fastening screws -arrows- on the actuator.
Fig 4: Locating Actuator Fastening Screws
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Loosen fastening screws -1- on the brake cover plate.
Fig 5: Identifying Screws On Brake Cover Plate
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Turn the wheel hub so that the actuator can be removed carefully. → Removing actuator
Fig 6: Securing Wheel Hub Actuator
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE > INSTALLING
SPREADER DEVICE (EPB) > INSTALLING SPREADER DEVICE FOR EPB
Information
If new brake discs and/or new brake shoes are installed on the vehicle, they must be worn in before
calibration (not PCCB!). → 468350 REWORKING PARKING-BRAKE SHOES
If a new actuator was installed, it must be confirmed in the Porsche System Tester.
>>Control unit overview<< >>Parking brake<< >>Drive links/Tests<< >>Confirm actuator
replacement<< .
1. NOTE: Do not twist brake shoe mountings when installing the actuator!
2. If using the same actuator again:
1. 2.1. Clean the spreader device carefully so as not to damage the dust boots.
2. 2.2. Visually inspect the dust boots for cracks.
3. Tighten fastening screws on the spreader device to the specified tightening torque. Tightening
Torque 20 Nm (15 ft. lb.) +60° (+44 ft. lb.)
Fig 1: Locating Actuator Screws
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Tighten fastening screws on the brake cover plate to the specified tightening torque.
Tightening Torque 8 Nm (6 ft. lb.)
Fig 2: Identifying Brake Cover Plate Screws
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Plug in electric plug connection -2- for the actuator -1- (-A- ) and lock it -a- .
Fig 3: Installing Plug Connection
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Clip wire harness -4- into the retaining clip -3- (-B- ).
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE > SUBSEQUENT
WORK
Information
If new brake discs and/or new brake shoes are installed on the vehicle, they must be worn in before
calibration (not PCCB!). → 468350 REWORKING PARKING-BRAKE SHOES
If a new actuator was installed, it must be confirmed in the Porsche System Tester.
>>Control unit overview<< >>Parking brake<< >>Drive links/Tests<< >>Confirm actuator
replacement<< .
1. Install brake shoes. → 468356 REPLACING BRAKE SHOES - section on "Installing"
2. Fit brake calliper. → INSTALLING REAR BRAKE CALLIPER - section on "Installing"
3. Fit wheel. → INSTALLING WHEEL - section on "Installing"
4. Adjust, grind down and calibrate the electric parking brake (EPB) using the Porsche System
Tester. → 468316 ADJUSTING PARKING-BRAKE SHOES → - section on "Installing"
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE (EPB) >
PRELIMINARY WORK > PRELIMINARY WORK FOR REMOVING AND INSTALLING
SPREADER DEVICE (EPB)
1. Remove the wheel. → REMOVING WHEEL - section on "Removing"
2. Move electric parking brake (EPB) into >>installation position<< using the Porsche System
Tester. To do this, select >>Parking brake<< in the control unit overview. Select >>Drive link
tests<< >>All<< >>Move to installation position<<.
3. Remove brake calliper and hang it at a suitable place in the wheel arch. → REMOVING REAR
BRAKE CALLIPER - section on "Removing"
4. Remove brake disc. → 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) -
section on "Removing"
5. Remove brake shoes. → 468356 REPLACING BRAKE SHOES - section on "Removing"
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE (EPB) > REMOVING
SPREADER DEVICE (EPB)
cardiagn.com
Information
The pictures shown in this document may differ from the original .
The spreader device (actuator) is located on the rear-axle wheel bearing housing instead of the
mechanical spreader device with the parking-brake cable.
1. Actuator
2. Tie-wrap - prevents twisting
Fig 1: Identifying EPB Actuator
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Release electric plug connection -2- at the actuator -1- (-a- ) and pull it off -A- .
Fig 2: Removing Plug Connection For Actuator
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Unclip wire harness -4- from the retaining clip -3- .
3. If the actuator -1- has to be reused, secure it in the brake shoe mountings with a tie-wrap -2-
to prevent it from twisting!
Fig 3: Securing Actuator To Prevent From Twisting
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Remove the fastening screws on the actuator -arrows- .
Fig 4: Locating Actuator Fastening Screws
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Loosen fastening screws -1- on the brake cover plate.
Fig 5: Identifying Brake Cover Plate Screws
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Turn the brake cover plate so that the actuator can be removed -arrow- .
Fig 6: Removing Actuator
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE (EPB) > INSTALLING
SPREADER DEVICE (EPB)
Information
If new brake discs and/or new brake shoes are installed on the vehicle, they must be worn in before
calibration (not PCCB!). → 468350 REWORKING PARKING-BRAKE SHOES
If a new actuator was installed, it must be confirmed in the Porsche System Tester.
>>Control unit overview<< >>Parking brake<< >>Drive links/Tests<< >>Confirm actuator
replacement<< .
1. Note: Do not twist the brake shoe mountings when installing the actuator!
2. If using the same actuator again:
1. 2.1. Clean the spreader device carefully so as not to damage the dust boots.
2. 2.2. Visually inspect the dust boots for cracks.
3. Tighten fastening screws on the spreader device to the specified tightening torque. → 4X00IN
TIGHTENING TORQUES FOR BRAKE MECHANICS
Fig 1: Locating Fastening Screws On Actuator
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Tighten fastening screws on the brake cover plate to the specified tightening torque. → 4X00IN
TIGHTENING TORQUES FOR REAR AXLE
Fig 2: Identifying Screws On Brake Cover Plate
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Plug in electric plug connection -2- for the actuator -1- (-A- ) and lock it -a- .
Fig 3: Installing Actuator Electric Plug Connection
cardiagn.com
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Clip wire harness -4- into the retaining clip -3- (-B- ).
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE (EPB) >
SUBSEQUENT WORK > SUBSEQUENT WORK FOR REMOVING AND INSTALLING
SPREADER DEVICE (EPB)
Information
If new brake discs and/or new brake shoes are installed on the vehicle, they must be worn in before
calibration (not PCCB!). → 468350 REWORKING PARKING-BRAKE SHOES
If a new actuator was installed, it must be confirmed in the Porsche System Tester.
>>Control unit overview<< >>Parking brake<< >>Drive links/Tests<< >>Confirm actuator
replacement<< .
1. Install brake shoes. → 468356 REPLACING BRAKE SHOES - section on "Installing"
2. Fit the brake calliper. → INSTALLING REAR BRAKE CALLIPER - section on "Installing"
3. Fit wheel. → INSTALLING WHEEL - section on "Installing"
4. Adjust, grind down and calibrate the electric parking brake (EPB) using the Porsche System
Tester. → 468316 ADJUSTING PARKING-BRAKE SHOES → - section on "Installing"
cardiagn.com
You might also like
- 2008 Porsche Cayenne S Variable Valve Solenoid Replacement100% (1)2008 Porsche Cayenne S Variable Valve Solenoid Replacement54 pages
- Seats 944, 968, 911, 928, 1985 - 1998 PDFNo ratings yetSeats 944, 968, 911, 928, 1985 - 1998 PDF874 pages
- Scheda Diagnosi: Diagnosis Sheet Fiche DiagnosticNo ratings yetScheda Diagnosi: Diagnosis Sheet Fiche Diagnostic20 pages
- Porsche 911 Carrera Owner's Manuals - CompressedNo ratings yetPorsche 911 Carrera Owner's Manuals - Compressed310 pages
- Engine Dfna DFNB DSGB DSGD DSGC Ea211 Evo Repair Manual EngNo ratings yetEngine Dfna DFNB DSGB DSGD DSGC Ea211 Evo Repair Manual Eng388 pages
- Maintenance Checklist: Macan/S/GTS/Turbo (2015-On)100% (1)Maintenance Checklist: Macan/S/GTS/Turbo (2015-On)2 pages
- Cayenne Technical Databrake Wear Limits TWNo ratings yetCayenne Technical Databrake Wear Limits TW341 pages
- Superior Performance Top Class Safety Excellent Reliability Comfortable Interiors Modern StylingNo ratings yetSuperior Performance Top Class Safety Excellent Reliability Comfortable Interiors Modern Styling2 pages
- Analysis of Fishing Ports in The Philippines100% (1)Analysis of Fishing Ports in The Philippines60 pages
- Bell 2806E Articulated Tractor Technical Specifications SheetNo ratings yetBell 2806E Articulated Tractor Technical Specifications Sheet4 pages
- Legal Concepts in Civil and Criminal LawNo ratings yetLegal Concepts in Civil and Criminal Law3 pages
- 2011 ELECTRICAL OEM Component Locations - F250-F550 Super Duty PDF100% (3)2011 ELECTRICAL OEM Component Locations - F250-F550 Super Duty PDF41 pages
- EnviCom-TG-193-RESILIENCE OF THE MARITIME AND INLANDNo ratings yetEnviCom-TG-193-RESILIENCE OF THE MARITIME AND INLAND91 pages
- The Seapower of The Coastal State Borresen1994No ratings yetThe Seapower of The Coastal State Borresen199430 pages
- Flowchart of The Rice Production ProcessNo ratings yetFlowchart of The Rice Production Process3 pages
- Pump / PTO Combination Reference Chart - (Chelsea & Muncie)No ratings yetPump / PTO Combination Reference Chart - (Chelsea & Muncie)4 pages
- KUL20 - AIT - Approved Method Statement - 2025No ratings yetKUL20 - AIT - Approved Method Statement - 202515 pages
- Top-Load Washing Machine: Model No. FWS1339ANo ratings yetTop-Load Washing Machine: Model No. FWS1339A11 pages