Porsche rear brakes and axel refurb

[Kidasters]

Well - I'm not the documentarian that Jim is.  I never take the time to stop and take pictures step by step.

 

A few weeks ago - it started with changing brake pads.  When the pistons wouldn't press back into the bores, I figured that means that it's time for new calipers.

 

PMB Performance in Sandy, UT does this.  For $313 (+100 for cores), you can get a set of refurb'd calipers.  I happened to have a really crappy set of rears for a Carrera out in the parts horde, so in the same day I sent them back some cores for my refund.

 

The new calipers look really nice

 

 

While I was at it, I also removed the left side 1/2 shaft

 

 

I have the new 1/2 shafts, as well as new lock washers.  Jim - if you decide to do your CV joints, and need new lock washers - call me.  I ordered some from McMaster-Carr, and the minimum order was 100.

 

So - in 2 hours this morning, I did the following:

 

Cleaned up old bleed screws (included running them through a die to clean all the crap out of the threads - 8 mm x 1.25).

Cut flexible line.  Suspend line over plastic container and catch 80% of the brake fluid that ran out (the other 20% is under the tile now.

Work really hard and free clip that locks flexible line end in place.  Remove and let soak in degreaser.

Unscrew hardline from old caliper. 

Clean up hardline with steel wool.  Probably need to paint it.

Remove old caliper bolts.  Holy smokes they are tight, and whoever did it last time used lock-tight.  Top one came off when I used my 24" ratchet wrench.  Bottom one came off with the help of a dead blow hammer.

Cleaned up bolts and washers in degreaser.  Ran bolts through 12 mm x 1.5 die to clean threads out.

Re-attach caliper.

Install new pads, wear sensor, retainer spring, pins.

 

Here's the end result:

 

Edited December 12, 2015 by Kidasters

[jgerock]

What is that under the shop rags??? Nice work!

[Kidasters]

Ha.  My next project....

 

[Kidasters]

Not many pictures again, but more progress.  I worked on the right side axle yesterday.  Went much faster, got the old half shaft out, pulled the caliper, got the old brake hose out, new hose in, new halfshaft in, new caliper in, new pads.  Today, I bled the system.  Thought I had it, but took a test drive and there's just a little bit of air left in the system.  Probably need to go around and bleed all 4 one more time.  Crap.  I don't have the energy for that today.

 

The good news is that I had help:

 

 

which reminded me of a time about 10 years ago, when I had help before:

 

 

They grow up fast.....

[jgerock]

Is it cold in Houston?

[Kidasters]

It was about 50 F today Jim, which is normal winter, and cold for us that have to suffer through 105+ summer.

[ray_]

What happened to the 2nd helper in the 1st pic?

 

 

Pretty girl!

 

Happy new year!

[Kidasters]

Ha.  Rosie?  We still have her too, though she no longer goes everywhere with us.

[Kidasters]

It never ends.

 

I finally got the air out of the brakes.  That's in good shape now.  However - more problems.  When I had the car out yesterday, it started spitting a little rain.  I turned on the wipers, and there's a "popping" noise when they are on, like it's a bad relay or something.  Now - on a Porsche, that particular relay (for the wipers) is on the firewall underneath the fresh air blower.  Oh fun.  

 

Also - turned on the fan and it squeaked and squealed.  Not good.

 

Pulled out the fresh air blower today.  Got the motor out, and will replace it - but also noticed the foam on the flappers is toast.  Ordered some of those off of e-bay for a million dollars.  Also ordered a new relay.  

 

It's always something.

[ray_]

Drove the project car today. Wipers have 2 speeds. Slow, and slower.

 

But, 70 here. I had to make sure the a/c still worked!

 

Cheers,

[Kidasters]

Ha.  It's really cold today.  was 40 when I got up - has warmed to 55.  Might get down to 32 tonight.  Brrrrrr.

[Kidasters]

Yesterday, ordered the following:

 

Blower motor, "squirrel cage" and mount

Relay

Gasket

heater hose

 

Hope to get it all before next weekend.  We'll see.

 

Jim - bet your car doesn't look like this:

 

[M3M3]

It's always something.

 

the project lists on old cars are never finished..... 

[Kidasters]

the project lists on old cars are never finished..... 

 

So true.

[Kidasters]

Still waiting for a gasket, but the relay has been changed, the fan motor changed and the foam around the flappers on the fan changed.

 

The gasket is the gasket that goes to the distribution pipe that goes down to the evaporator in the smuggler's box.  I'm also waiting for a small hose.  

 

Here's the rebuilt blower system: