Doing the 996 brake conversion on Monday

**als2** · 3 November 2009, 15:36

Cant help with ur answers unfortunately but im really intrested in the replies as its on my shopping list for santa!

Just seemed to be sooooo many options and opinions so would love to know how you get on.

AL

**GazzaG60** · 3 November 2009, 15:55

looks ok.

firstyl tools.

get some brake spanners. more than one. these will make or break the job.

the 4 pots are not that big so fit easily. the 6 pots have a few more issues. brake balance will be fine.

the frontmount will require more work. the removal of the bumper is a bit of a pain if the fittings top the body are corroded. xmember removal is easy, refitting can be a pig.

notmany special tools needed for either but a power bleeder from motive products i can recommend.

**Le S2 Audi** · 3 November 2009, 17:19

Originally posted by Colesy

4 x metal plates with round bits on that fit into the pistons (excuse the description!)

And I will be buying 2 litres of either Halfords Dot 5.1 or Castrol Super response Dot 4 brake fluid this weekend.

I do also have some questions:

I had read quite widely that to fit these discs I would need to file down the pins of the calipers but when I had a look there was a least 4-5mm of clearance (total) already, will this be ok?

It's an ABY coupe with 18" wheels btw!

Thanks everyone!

4 x metal plates with round bits on that fit into the pistons (excuse the description!)
Porsche call these dampers....

You may want to get a set of new brake pad springs from Porsche... Not that dear..

I am not sure on this but shouldn't you JUST use DOT 4 Fluid...??? ANYONE!!!

The Disc pins need 1mm off Each Side this is JUST to accomodate the disc's and has no effect on the caliper or its operation as they are just Guide Pins... AFAIK.

Mine are fine....

Just one thing to check before you start is to make sure the Mounting bracket to Suspension arm bolts you have are the CORRECT Thread & Pitch.... This held me up doing my Upgrade....

Tools; A Torque Wrench!!! Aswell...

Have Fun...

Just one comment... Go steady for the first few hundred miles as I nearly warpped my discs as they are 2mm thicker than the Porsche ones, but the pads are desgined for the 28mm ones...

**sjw185** · 3 November 2009, 18:43

[QUOTE=GazzaG60;446891]looks ok.

firstyl tools.

get some brake spanners. more than one. these will make or break the job.

11mm is your man got a snap on one from ebay best money I ever spent.

Attached some photos of my intercooler mod

Used original piece for mounting bolts and welded a new plate to crossmember just took the whole crossmember off and my mate welded it for me.

Attached Files

**MidnightBlueS2** · 3 November 2009, 19:13

[QUOTE=GazzaG60;446891]

get some brake spanners. more than one. these will make or break the job.

[QUOTE]

Couldn't agree more ! When I did my upgrade, the brake line nuts were the only issue I had.

**Cymru1** · 3 November 2009, 20:07

special tools - yes, a digi cam, pen and paper! Full write-up for the forum !!

**PistonBroke** · 4 November 2009, 00:20

I did exactly the same job a couple of weeks ago, I know it's a tried and tested mod but I was still amazed how easily everything fitted together and all lined up just as if it had all been designed to go together in the first place. Three components from three different cars (disc, caliper and carrier) and it works spot on!
It sounds like you have everything you need on your list, presumably you also have the main pin (plus the little 'R' shaped clip that secures the pin) and spring thingy that holds the pads in.
You don't mention what brackets you have, I used RS2 with 323mm discs and the discs sit smack in the middle of the calipers with about 2mm of clearance between the disc and the shortened locating pins and also clear the main pad 'holding' pin by 2-3 mm. The pads only leave about 1mm of the disc untouched on the outer edge and about 2mm on the inner edge. ( see pics )

I would agree on the brake spanner, particularly for undoing the brake pipe fittings, I almost rounded off one or two using an ordinary spanner but then bought a proper one, I think 11mm, and it made a huge difference. Definately worth buying if you don't have one.
Actually you might find it difficult to undo the hard line on the inner wing from the flexible rubber hose, I had to use quite a bit of heat to get it to let go. If you have to do this on yours make sure you have disconnected the other end of the rubber hose at the caliper first to release any pressure build up as they can go bang!!
I used a single Goodrich braided hose from the inner wing straight to the caliper and it works a treat.

I think I had about 1mm of clearance between the disc and the caliper pins at either side when I trial fitted them and then filed off about 1.5mm each side. If you already have 2 - 2.5mm either side (4-5mm total) is it possible the pins could have already been shortened?

As has been mentioned, I think DOT 4 brake fluid is what you should use, I took the opportunity to flush through and bleed the whole system front and rear and now have a really firm pedal. 2 litres should be OK to do that.

Again as already mentioned, no problem with brake balance - with mine, it doesn't feel that different in normal use but when you push hard there's a lot more braking power available. Gives a lot more confidence. Hope that helps

Attached Files

**T2Andy** · 4 November 2009, 01:34

If using RS2 caliper brackets you may need to put a thick washer between the caliper and bracket just to bring it back slightly for better pad to disk fitment ,i had to do this .

**T2Andy** · 4 November 2009, 01:38

Also use some PLASTILUBE on the back Of the pad backing plates ,this will eliminate
any droning or squeeling which affects some set ups .

**GazzaG60** · 4 November 2009, 09:47

whats plastilube?

im from the copper grease school

how does the washer affect the stresses applied to the bolt rather than the bracket?

**Alam** · 4 November 2009, 10:32

Originally posted by GazzaG60

whats plastilube?

plastilube Linky

If you are friendly with your local dealers they'll have some.
Alternative is "Ceratec" brake lube, same stuff in a different tube.
Seach ebay for ceratec.

**GazzaG60** · 4 November 2009, 12:34

you learn somfink everyday.

i have no backing plates on my pads. pistons have ceramic like covers over so no insertable piece. never rattles at all.

**Colesy** · 4 November 2009, 13:12

Thanks for all the replies everyone.

I've added Plastilube & brake spanner to the shopping list!

Originally posted by PistonBroke

It sounds like you have everything you need on your list, presumably you also have the main pin (plus the little 'R' shaped clip that secures the pin) and spring thingy that holds the pads in.

I've got all the bits as sold in the kit sold here:

http://www.pelicanparts.com/cgi-bin/...)%2C%20Each%09

Is that the "spring thingy" you mentioned in the picture?

The brackets are aluminum ones bought from the forum so should be good.

Originally posted by Le S2 Audi

4You may want to get a set of new brake pad springs from Porsche... Not that dear..

You don't happen to know the part number for these do you?

Cheers

**PistonBroke** · 4 November 2009, 18:03

I've got all the bits as sold in the kit sold here:

http://www.pelicanparts.com/cgi-bin/...)%2C%20Each%09

Is that the "spring thingy" you mentioned in the picture?

The brackets are aluminum ones bought from the forum so should be good.

[/QUOTE]

"spring thingy" is the technical term, looks like it's also known as a "pad retainer"

.

Yes, all the bits I mentioned are included in the pelican parts photo - you can also see the same parts in my photos posted earlier. I think Le S2 Audi is referring to the same thing when he mentioned brake pad springs. You have everything you need as far as I can see.

If the brackets have the same dimensions as the RS2 ones it should all line up perfectly.

Doing the 996 brake conversion on Monday

Doing the 996 brake conversion on Monday

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