Front Brake Disc, PCCB Rotors
Removing and installing the front PCCB brake disc
Removal
Caution. PCCB (Porsche Ceramic Composite Brake): Danger of material damage during wheel removal/installation (danger of damage to brake discs).
^ Use assembly aids (assembly pins) in order to exclude any possibility of heavy contact of the wheel with the brake disc. The assembly aids t2 assembly pins) are located in the luggage compartment.
1. Screw the 2 assembly aids (assembly pins), instead of 2 wheel bolts, into the wheel hub before wheel removal/installation. During removal, first remove the three remaining wheel bolts and remove the wheel carefully, without touching the brake discs.
2. Subsequently (after the wheel is disassembled) remove the 2 assembly aids (assembly pins) again.
Note. In order to gain better access for assembly work, it is beneficial to tom the wheels fully either to the right or the left.
3. Press the electrical lead for the speed sensor/wear indicator out of the holder.
4. Undo the plug coupling for the speed sensor/wear indicator on the wheel carrier.
5. Loosen holder for brake line at wheel carrier.
6. Disengage the electrical lead for the wear indicator from the clips.
7. Set the brake pads back slightly with the piston resetting fixture.
8. Undo the brake caliper on the wheel carrier and hang it in a suitable place in the wheel well (do not open the brake hydraulics.).
9. Take off the brake disc after removing the countersunk screws.
Explanation of 2-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 chamber -2- with 10 screws (M6)-3-.
^ The complete brake disc only is available as a spare part (disc + brake-disc chamber).
^ Do not separate the brake-disc chamber -2- and brake disc -1from each other. It is also not permissible and not necessary to turn the screws -3-. The screws are safeguarded against turning by compression in the bushing.
^ It is essential that the tightening torque of the 10 screws is not changed (do not turn the screws) as this will have a negative effect on the sound behavior.
1 - Brake disc
2 - Brake-disc chamber
3 - Screw (10 ea.)
Installation
Note.
^ Do not confuse right and left brake discs during assembly. Distinguishing characteristic: Involute shape, identification and spare part number (SP No.).
^ The front PCCB brake discs of the Turbo and GT2 are different. Use the correct brake disc when replacing.
^ The front PCCB brake discs are marked with GT or Turbo, R = right or L = left and with an arrow for the direction of rotation (additional Whence to right or left).
^ Spare part on left-hand side - third group number is odd. Example: SP No. Left brake disc = 996.351.031.92.
^ Spare part on right-hand side - third group number is even. Example: SP No. Right brake disc= 996.351.032.92.
1. Check that all parts are in perfect condition 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. Fit the brake disc.
Note.
^ Replace the brake caliper fastening screws after each removal.
^ The brake caliper fastening screws of the GT2 and Turbo with PCCB are 8 mm longer (85 mm) than on the 911 Turbo with cast iron brake discs (77 mm).
5. Fit brake caliper with new fastening screws. Tightening torque of the fastening screws = 85 Nm (63 ft. lbs.).
6. Mount wheel. For a wheel installation, 2 assembly aids (assembly pins) must be screwed into the wheel hub.
Note on bedding in the 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 a brake disc change.