Work Procedure
1. Position vehicle on hoist and raise.2. Remove all wheels.
Converting The Front Axle
The procedure described below must be carried out on both the left and right side of the vehicle.
Removal: Front Axle
3. Remove the brake caliper and the cast-iron brake discs (left/right); refer also to 911 Turbo (996) Technical Manual, Group 46-6
3.1 Open retainer on plug connection for the electrical wire of the speed sensor/wear indicator on the wheel carrier and pull off plug for wear indicator.
3.2 Undo the brake line on the brake caliper and close the brake line with suitable plug.
3.3 Loosen the brake caliper at the wheel carrier (2 hexagon socket head bolts a/f 10) and detach from the brake disc.
3.4 Remove the brake disc (loosen 2 phillip countersunk screws).
3.5 Unscrew brake line on brake hose. Seal off the brake hose with the corresponding plug.
Installation: Front Axle
4. Fit the ceramic brake disc and the brake caliper (left/right) according to the instructions in the 911 Turbo (996) Technical Manual, Group 46-6.1 (Supplement 17).
Note:
Do not mix right and left brake discs when fitting! Distinguishing characteristic:
The front ceramic brake discs can be identified by the marking "turbo R" right or "turbo L" left and two arrows on each to signify direction of rotation.
Caution!
PCCB: Danger of material damage when removing/fitting the ceramic brake discs.(There is a particular danger of damage to the brake disc edges)!
> Protect the ceramic brake disc from rough handling and do not strike it with anything.
4.1 Screw new brake line (996.355.587.03 left/996.355.588.03 right) and the brake hose together. Do not tighten completely yet.
4.2 Clean the flat and centring surfaces of the wheel hub and apply a thin layer of Optimoly TA to the centering surface.
4.3 Position the ceramic brake disc (996.351.031.02 left/996.351.032.02 right) and fasten to the wheel hub using 2 countersunk screws (crosshead) M 6.
Tightening torque: 10 Nm (7.5 ftlb.).
4.4 Fit the new brake caliper for PCCB (996.351.431.30 left/996.351.432.30 right) using 2 new fastening screws M12 x 1.5 x 85 (999.067.047.09).
Tightening torque: 85 Nm (63 ftlb.).
4.5 Screw brake line to the brake caliper and tighten to the brake hose and brake caliper. Tightening torque: 12 - 14 Nm (9 10 ftlb.).
Caution!
PCCB: Danger of damage to the brake calipers when fitting the brake pads. (The pistons in the brake calipers are fitted with ceramic inserts)
> The pistons must not be reset with a screwdriver or similar tool.
> The pistons must only be set back into the brake calipers with a piston_resetting fixture.
4.6 Fit the disc brake pads according to the instructions in the 911 Turbo (996) Technical Manual, Group 46-4.1 (Supplement 17)
4.7 Fit the brake pads for the ceramic brake discs (996.351.947.01 set) with new vibration dampers (996.352.086.01 - 2 x 6 items) using new fastening components (are enclosed with the new brake calipers). The vibration dampers on the lower pistons must be positioned with the cut-outs facing the brake pad guide pin as the vibration damper will otherwise be deformed! Do not grease the pad backing plate (reverse side)!
Tightening torque: Retaining pin on the brake caliper 25 +/-3 Nm (19 +/-2 ftlb.).
4.8 Install warning contact wire with warning contact (wear indicator - 996.612.347.00). Fasten the wire to the brake line with the existing rubber holders (Figure 1, arrows).
4.9 Insert plug of the electrical line for the wear indicator into the plug connection on the wheel carrier and close plug retainer.
Note:
Do not mount wheels onto the front axle yet; brakes still have to be bled!
Converting The Rear Axle
The procedure described below must be carried out on both the left and right side.
Removal: Rear Axle
5. Remove the brake caliper and the cast-iron brake discs (left/right); refer also to 911 Turbo (996) Technical Manual, Group 46-7
5.1 With a screwdriver, turn the adjustment device for the hand brake towards "release" through a wheel bolt threaded hole.
5.2 Open the plug connection on the wheel carrier for the wear indicator electrical wiring and remove the connector.
5.3 Separate the brake line to the brake caliper from the brake hose. Seal off the brake hose with the corresponding plug. Brake line and holder can remain mounted on brake caliper (will be replaced).
5.4 Loosen the brake caliper at the wheel carrier (2 hexagon socket head bolts a/f 10) and detach from the brake disc.
5.5 Remove the brake disc (loosen 2 phillips countersunk screws).
Installation: Rear Axle
6. Fit the rear ceramic brake disc and the brake caliper (left/right) according to the instructions in the 911 Turbo (996) Technical Manual, Group 46-7.1 (Supplement 17).
Note:
Do not mix right and left brake discs when fitting! Distinguishing characteristic:
The rear PCCB ceramic brake discs can be identified by the marking R = right or L = left and two arrows to signify direction of rotation.
Caution!
PCCB: Danger of material damage when removing/fitting the ceramic brake discs. (There is a particular danger of damage to the brake disc edges)!
> Protect the ceramic brake disc from rough handling and do not strike it with anything.
6.1 Clean the flat and centering surfaces of the wheel hub and apply a thin layer of Optimoly IA to the centering surface.
6.2 Position the ceramic brake disc (996.352.031.02 left/996.352.D32.02 right) and fasten to the wheel hub using 2 countersunk screws (crosshead) M 6.
Tightening torque: 10 Nm (7.5 ftlb.).
6.3 Adjust the parking brake shoes (see 911 Turbo (996) Technical Manual, Group 46-9).
6.4 Pre4it new brake caliper for PCCB (Figure 2, Item A)
996.352.423.30 left/996.352.424.30 right with: new holder (Figure 2, Item B)
996.355.503.10 left/996.355.504.10 right, new brake line b (Figure 2, Item C)
996.355.585.10 left/ 996.355.586.10 right and previous holder (plastic) for electrical line of wear indicator (Figure 2, Item D).
6.5 Fit the pre-mounted brake caliper using 2 new fastening screws M12 x 1.5 x 85 999.067.047.09).
Tightening torque: as Nm (63 ftlb.).
6.6 Screw brake line (996.355.585.10 left/
996.355.586.10 right) together with the brake hose and tighten on brake caliper and brake hose (Figure 3, arrows).
Tightening torque: 12 - 14 Nm (9 - 10 ftlb.).
6.7 Fit the disc brake pads according to the instructions in the 911 Turbo (996) Technical Manual, Group 46-5.1 (Supplement 17). Fit the brake pads for the ceramic brake discs (996.352.947.01 set) with new vibration dampers (996.352.086.01 - 2 x 4 items) using new fastening components (are enclosed with the new brake calipers). Do not grease the pad backing plate (reverse side)!
Caution!
PCCB: Danger of damage to the brake calipers when fitting the brake pads. (The pistons in the brake calipers are fitted with ceramic inserts)
> The pistons must not be reset with a screwdriver or similar tool.
> The pistons must only be set back into the brake calipers with a piston resetting fixture.
6.8 Fit new warning contact line with warning contact (wear indicator 996.612.348.00).
7. Bleed brakes; see 911 Turbo (996) Technical Manual, Group 47-2).
Caution!
PCCB: Danger of material damage when removing/fitting the wheels (danger of damage to the brake discs)!
> Protect the ceramic brake disc from rough handling and do not strike it with anything.
> Use assembly aids (2 assembly pins) in order to exclude any possibility of heavy contact of the wheel with the ceramic brake disc.
Note:
Screw the two assembly pins, instead of two wheel bolts, into the wheel hub before wheel mounting (removal) (Figure 4). Only then position the wheel and screw in the 3 unused wheel bolts. Remove the assembly pins and screw in the 2 remaining wheel bolts.
8. Fit all wheels in this manner.
Wheel bolt tightening torque: 130 Nm (96 ftlb.).
9. After mounting the wheels, place the new assembly pin (999.571.074.30) from the conversion set into the tool kit together with the assembly pin already present.
10. New collapsible spare wheel for PCCB (996.362.020.01). Due to the larger brake calipers, a large collapsible spare wheel 185/60 - 17 93P is required together with PCCB (previously 165/70 - 16 92P). Tire pressure for the 17-inch collapsible spare wheel when mounted at front or rear = 2.8 bar excess pressure (previously 2.5 bar).
10.1 Remove the existing collapsible spare wheel.
10.2 Affix two tension straps (996.361.411.00) opposite to each other onto the new collapsible spare wheel (996.362.020.01) when deflated. Jo do so, pull the straps through the wheel (Figure 5) and position around the collapsible spare tire. Position the straps in such a way that the strap fastenings are on the inner side of the wheel.
10.3 Close strap fastenings (Figure 5, arrow). Retighten straps when necessary.
10.4 Place the new collapsible spare wheel in the spare wheel recess so that the tension straps lie at the front and at the rear.
10.5 The new collapsible spare wheel (17-inch wheel) cannot be stowed in the spare wheel recess without securing it with the tension straps.
Installation of Adhesive Warning Labels
10.6 Self-adhesive label (country-specific) - note top speed:
Attach the self-adhesive label to the new collapsible spare wheel (Figure 6, arrow).
928.701.150.00 Self-adhesive label for RoW
996.361.701.20 Self-adhesive label for USA/Australia
996.361.701.21 Self-adhesive label for Canada French
10.7 Self-adhesive label (country-specific) - information on the new size and higher tire pressure of the collapsible spare wheel: Stick new self-adhesive label over the previous self-adhesive label on the inner side of the front luggage compartment lid (Figure 7, arrow).
996.701.287.48 Self-adhesive label for RoW
996.361.287.49 Self-adhesive label for USA/Australia
996.361.287.50 Self-adhesive label for Canada - French
11. Remove vehicle from the hoist.
Warning!
Observe the break-in period for the new brake pads! Advise the customer accordingly.
> In the case of ceramic brake pads, a slightly longer break-in period is required than with cast iron brake discs.
> New brake pads must be worn in (break-in period); their optimum braking effect is therefore not reached until after a few hundred miles. The slightly reduced braking effect must be compensated for by increased pressure on the brake pedal.
12. Perform a function test on the foot brake and the parking brake. Carry out a test drive or perform a test on the brake test stand.
Important Note:
Brake pads for sporting or racing events! Please advised the customer after conversion of the braking system to PCCB of the following warning!
Warning!
When converting the braking system of the 911 Turbo to the PCCB, "Comfort Brake Pads" are installed. These brake pads are not suitable for vehicles which are used for sporting events or on closed racing circuits. Increased wear of the brake pads and an excessive demand on the brake discs due to an increased temperature.
> Other brake pads (see part nos. below) must be installed in vehicles which are used for sporting events or on closed racing circuits.
> New brake pads must be worn in (break-in period); their optimum braking effect is therefore not reached until after a few hundred miles. The slightly reduced braking effect must be compensated for by increased pressure on the brake pedal.
> During this break-in period, the brakes should be subjected to full stress when travelling at high speed only in emergencies.
> These brake pads can cause squeaking noises.
Parts Information:
Working Time: