Rear Brake Disc, PCCB Rotors
Removing and installing the rear 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 12 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 3 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.
3. With a screwdriver, turn the adjustment device towards "release" through a wheel bolt threaded hole.
4. Set the brake pads back slightly with the piston resetting fixture.
5. Open the plug connection on the wheel carrier and pull out the plug for the brake pad wear indicator.
6. Remove the brake caliper from the wheel carrier and suspend it in the wheel arch (do not open brake hydraulics). First, pull out the electrical wires on the brake caliper holder and the brake pad wear wire on the wheel carrier holder.
7. Take off the brake disc after removing the countersunk screws. If a stuck brake disc cannot be removed, evenly screw hexagon-head bolts into the two Me threads of the brake disc, thereby pressing off the disc.
Explanation of 2-part brake disc
^ The PCCB brake discs consist of two parts on the front and rear axles (illustration shows front brake disc). 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 -1- from each other. It is also not permissible and not necessary to turn the screws -3-. The screws are safeguarded against turning by the 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 brake discs are marked with R = right or L = left and with an arrow for the direction of rotation (additional difference of right or left).
^ Spare part on left-hand side - third group number is odd. Example: SP No. Left brake disc = 996.352.031.02.
^ Spare part on right-hand side - third group number is even. Example: SP No. Right brake disc= 996.352.032.02.
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.
5. Adjust the parking brake shoes and parking brake cables.
Note.
^ Replace the brake caliper fastening screws after each removal.
^ The brake caliper fastening screws for PCCB brake discs are 8 mm longer (85 mm) than on cast iron brake discs 177 mm).
6. Fit brake caliper with new fastening screws. Tightening torque of the fastening screws = 85 Nm (63 ft. lbs.).
7. 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.