Flexing 996

[mark_s2]

I agree with the above - if your calipers 'flex' by the amount you state I would have serious concerns. I have 996 monos fitted to my S2 avant and apart from squeeling since fitting textar pads their performance is great.

If you are using machined cupra mounts & 314mm A8 discs can I ask who machined the mounts? Might be worth hooking them off and checking they are square (as in the two machined surfaces are at 90 degrees to each other).

Mark

[Jas11n]

I doubt when it was designed it was massively over engineered.

Seriously over engineered when you compare it to the flimsy looking RS2 bracket.





Sorry, I don't know the answer, my 996's have a really hard pedal, I've been through 3 sets of textars (just fitted fourth) and am still on the originally fitted 314mm zimmerman's after 3 years and 30k miles. Disc is nearing the end of it's life now.

Hope you get it sorted Rob.

[bertman]

Are both calipers exhibiting the same kind of deflection? I just don't think the load you can apply will bend them that easily. If it was moving 2-3mm I would be looking for a crack.

Martin,I am not sure wether both were checked,but I have requested that he checked the other side aswell,will find out tommorow.
I can honestly say the amount of deflection was quite shocking,I thought you should see a crack to say the least,but there is no evidence of one,unless it somehow is beneath the paint.
I will try and get a video of the deflection and post it up if I can,and you will see what I am on about.

[bertman]

Seriously over engineered when you compare it to the flimsy looking RS2 bracket.





Sorry, I don't know the answer, my 996's have a really hard pedal, I've been through 3 sets of textars (just fitted fourth) and am still on the originally fitted 314mm zimmerman's after 3 years and 30k miles. Disc is nearing the end of it's life now.

Hope you get it sorted Rob.

Thanks Jas,I hope I do to mate,this is been going on for too long .As i put in previous threads,have driven two other forum members cars and both pedals were hard.And lots of other people have said that is quite the norm.

[HPmuirt]

Are both calipers exhibiting the same kind of deflection? I just don't think the load you can apply will bend them that easily. If it was moving 2-3mm I would be looking for a crack.

Wot he said

1. Are they both moving or is it on just one caliper?
2. How long have they been on the car and were they new calipers or 2nd hand?
3. If 2nd hand, where did they come from....a crashed Porsche?

The bracket is a red herring in terms of cause. Have you seen the thickness of the Seat item? Even after machining it is twice as thick as the RS2 version.

However, I wonder if the Seat bracket could be stopping the inner side from flexing, but even after machining there is a good few mm gap between the centre of the bracket and the caliper wall.

A casting of that size simply cannot 'flex' by 2-3mm so I agree that it is cracked.

Since this is not happening to most of the older 996 systems, one has to assume that this is not a generic flaw with the Brembo design or an overuse problem due to the extra weight of the S2 over the Porsche.....I hope.

All in all, my guess is that it is terminal and you need new calipers....sorry

Cheers n

Si

[bertman]

Wot he said

1. Are they both moving or is it on just one caliper?
2. How long have they been on the car and were they new calipers or 2nd hand?
3. If 2nd hand, where did they come from....a crashed Porsche?

The bracket is a red herring in terms of cause. Have you seen the thickness of the Seat item? Even after machining it is twice as thick as the RS2 version.

However, I wonder if the Seat bracket could be stopping the inner side from flexing, but even after machining there is a good few mm gap between the centre of the bracket and the caliper wall.

A casting of that size simply cannot 'flex' by 2-3mm so I agree that it is cracked.

Since this is not happening to most of the older 996 systems, one has to assume that this is not a generic flaw with the Brembo design or an overuse problem due to the extra weight of the S2 over the Porsche.....I hope.

All in all, my guess is that it is terminal and you need new calipers....sorry

Cheers n

Si

Si,will find out tommorow if the other side is fubar aswell.The calipers were off another forum member,who was running them on his car until an upgrade,was told that they were ....OK
I have had them on my car for well under a year,and this problem has been with me since the whole lot was put on...since day one.
I think new is the way foward because you have no idea what you may be getting second hand.Everyone assumes that these calipers are indestructible,but will find out tommorow if they are beyond repair

[Sonic]

Sounds pretty messed up!

I have the SEAT carriers also and they are pretty chunky bits of kit. My callipers are only a year or so old (2007) and have been on the car since December. I wouldn't say the pedal is spongy but it certainly travels a long way i.e. you can always press it harder if you need to :mischeif: It only feels like you are exerting 20% of the braking power for the top 50% of the pedal.

Hope you get it sorted mate, and dont have to splash out on a new set callipers!

[bertman]

Sounds pretty messed up!

I have the SEAT carriers also and they are pretty chunky bits of kit. My callipers are only a year or so old (2007) and have been on the car since December. I wouldn't say the pedal is spongy but it certainly travels a long way i.e. you can always press it harder if you need to :mischeif: It only feels like you are exerting 20% of the braking power for the top 50% of the pedal.

Hope you get it sorted mate, and dont have to splash out on a new set callipers!

Thanks mate,you really do not want to know how much I have spent trying to resolve this blooming problem,and that's with getting married aswell....and nearly getting dirvorced because of this issue
I really more than anything just want the set up to work as it should.I have had a few glimpses of how good they can be,and it leavea you wanting more
I basically have a whole new breaking system on the car apart from the rear callipers,so at least there won't be any probs when the caliper issue is resolved.

[bertman]

So the Forum consensus is that one or maybe more of my calipers is doing something it shouldn't,basically they are boogered.
So what are the alternatives in regard to calipers,are there any other makes that will fit on the set up I have?
Or shall I try another pair of 996 calipers.
This has got to be the answer afaik

[A80Avant]

why dont you just get the original RS2 ones Big reds and be over with it?My mechanic(back in Greece) has stated that these seem so robust,you never have to service them.Even today after all these years of newer models and production caliper brakes with 28 pistons,he still wants a set of those to fit his BMW!!!

[bertman]

Love to get a set but that means forking out lots more wedge,but I suppose that is what I am going to have to do.
With the RS2 calipers I have heard that they need servicing every 6 months or so to remove all brake dust build up.But that is not much of a problem as long as they WORK!

[A80Avant]

i have only serviced them once in 14 years.who ever said about servicing every 6 months???

Only replaced the shims from vagparts ones,textar pads all over,occasional cleaning with a bit of carb/brake cleaner fluid(without taking the wheel off) and no squeeks no problems!I guess if you find a used set,just give them a good service initially and respray if needed as i heard of corrosion issues here in the UK.Mine,other than simple spray paint(caliper) for looks purposes,never had an issue with corrosion either.And if i do after 15 years of use,well then,ok!

You can get a nice refurb set from ebay.de for 650euros

[newsh]

That amount of flex seems scary Rob.The creaking I was getting from my drivers side caliper has got louder, maybe I've got something like this going on too. Will get someone to mash the pedal while I have a look.

[terrybullwon]

They are black,so its diffucult to see if they have been cooked

They were used hard, but they worked just fine after track days and car club events. The only thing i would say, they were stood for 9mths before you put them on

[Fat Audi 80]

I agree with the others. they sound cracked or damaged to me. There is no way on earch a "good" caliper should "open" at all, even with the S2 Master Cylinder and brake bomb.

Unfortunately I think another set of calipers is the only cure.

I would also double check your set up to make sure the bracket have the correct offset etc, in case that is a contributary factor.

Best of luck.

Cheers,

Steve.