I'm the owner of a 996 turbo with ceramic brakes, and I do all the maintenance myself.

I need to replace to brake discs, but these are bolted to the hub. Does any one know if I need to replace these bolts to?
and what is the torq for these bolts ?

Thanks for your help.

 

You can reuse the hub bolts but most techs would recommend they be replaced with new.

 

On page 1923 of the manual forward -

6 50 19 Removing and installing the front PCCB
brake disc
 Removal
 Explanation of 2−part brake disc
 Installation
top of page
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 (2 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 turn 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.
46 50 19 Removing and installing the front PCCB brake disc 1923
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.
top of page
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 −1− from 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 behaviour.
·
1 Brake disc
2 Brake−disc chamber
3 Screw (10 ea.)
top of page
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 diffence 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.
·
einordnung
Removal 1924
1. Check that all parts are in perfect condition and replace them if necessary.
2. Clean the levelling and centring 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 ftlb.).
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.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
einordnung
Installation 1925
46 53 19 Removing and installing the rear PCCB
brake disc
 Removal
 Explanation of 2−part brake disc
 Installation
top of page
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 (2 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
46 53 19 Removing and installing the rear PCCB brake disc 1926
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 M8 threads of the brake disc, thereby pressing off the disc.
top of page
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 behaviour.
·
1 Brake disc
2 Brake−disc chamber
3 Screw (10 ea.)
top of page
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 centring surfaces on the brake disc and wheel hub.
einordnung
Removal 1927
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 (77 mm)!
·
6. Fit brake caliper with new fastening screws. Tightening torque of the fastening screws = 85 Nm (63 ftlb.).
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.
996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841
einordnung
Installation 1928

So yes, replace all the hardware.

Cheers,

 

Thanks, but I need to know the torq from these 10 screws...and do I have to replace them?


· 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 behaviour.

 

Henk, it is buried in there, replace all the hardware.

I am just about to do my pads for my PCCBs and didn't realize that it is recommended that I get new vibration dampers, expanding springs, retaining pins and retainer - all of which I am ordering today.

The costs associated with new fasteners is quite insignificant when compared to replacing one PCCB disc.

 

1. Check that all parts are in perfect condition and replace them if necessary.

As the car is no longer new, parts will not be 'perfect' - I read that to mean 'replace'.

Cheers,

 

"Perfect condition" does not exclusively mean "new". It is up to the individual to evaluate.

 

They always say to replace everything though the dampers, clips, etc, are almost infinitely reusable. But for the $10k you’re spending on disks it’s trivial. Have you considered just going to steel? Curious what caused the disks to need replacement? Did you track them? I thought they should pretty much last as long as the car otherwise.

 

Porsche AG lists life expectancy at 300,000kms - however, a 2.5mm crack or chip (most likely from not using the wheel aligners when removing wheels) along the leading edge of the rotor will render them useless immediately.

I find it interesting that Suncoast sells replacement rotors for $11k USD per axle (approx $5500 per), yet there is this interesting place that can apparently 'renew' them, for considerably less.

https://www.rebrake.de/?lang=en

As I only have 84,000kms on my PCCBs, it should be awhile before I go looking.

 

This. Seriously, you are replacing PCCB rotors and are considering re-use of $20 worth of bolts?

 

I want to replace them because:

I have a cayman s with ceramic brakes, and want to place these on my 996 turbo. Only the hubs ( or like the manual says 2 Brake−disc chamber) from the cayman and 996 turbo on the back are not the same.
So I have bougth the right hubs for the 996.

The only thing I have to do is to mount the ceramic discs from the cayman on the hubs from the 996.

So I need to know, whats the Torq for these 10 M6 screw, and can I re-use them, or where can I buy new one's.

 

All these do is keep the rotor snug against the hub when you’re changing wheels. Not a bad idea to replace as these bolts do tend to corrode and seize up and are usually just a philips head. I always apply anti-seize for that reason. Hand tight is fine.

 

I recently started tracking my 2002 GT2 (996) w/ 57k miles and OEM PCCB rotors and Pads. I need front pads and am curious what to use (50/50 track road use). I am thinking of converting from PCCB to iron all the way round and wonder what conversion kit is best, without needing to change calipers.
TIA for any comments

 

I have looked at coverting to the Giro Disc setup, but once I found these fellas in Europe, I am much happier with continuing to maintain and own PCCBs.

https://www.rebrake.de/?lang=en

 

for simplest fitment, use 350mm 997GT3 iron discs all-round, and 996 GT3 iron spec pads
can also use Cayenne fitment front 350mm discs
oem pads for street, PFC or Ferodo or Pagid or other flavour of choice pads for track