REMOVING AND INSTALLING THE FRONT DISC BRAKE PADS

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1 Page 1 of 5 REMOVING AND INSTALLING THE FRONT DISC BRAKE PADS It is essential to observe the following points when changing brake pads. Use brake pads of the correct quality (in accordance with spare parts catalogue). Replace vibration dampers each time the pads are changed. Fig. 6: Identifying Vibration Dampers The vibration dampers (damper plates with integrated compensating masses) have an adhesive protective film. The protective film must be pulled off before installation. The pad backing plates (rear side of the brake pads) must not be greased. REMOVAL Remove the retainer (arrow) and extract the retainer pin inwards.

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3 Page 3 of 5 Fig. 7: Removing Brake Pad Retainer Pull out the warning contact wire on the brake caliper and remove the warning contacts from the brake pad plates. Replace warning contacts if the core of the wire is worn or worn through. The warning contact can continue to be used if there are only scrape marks on the plastic part of the warning contact. Remove brake pads with a brake pad puller. It is essential to observe the following notes. Pull out brake pads together with the vibration dampers. If this is not possible (depending on wear of the brake pads), use a spatula to detach the vibration dampers from the brake pad plate before removing the pads. In both cases, first set back the brake pads as far as possible with the piston resetting fixture. If necessary, first remove some brake fluid by suction from the brake fluid reservoir. INSTALLATION Before installation of the brake pads, check the wear of the brake discs. For minimum thickness of the brake discs, see TECHNICAL DATA/BRAKE WEAR LIMIT CARRERA, TECHNICAL DATA/BRAKE WEAR LIMIT - GT3, TECHNICAL DATA/WEAR LIMIT BRAKE - GT3 RS AND GT3 AS OF MODEL YEAR 2004, TECHNICAL DATA/BRAKE WEAR LIMIT CARRERA 4, TECHNICAL DATA/BRAKE WEAR LIMIT CARRERA 4S or TECHNICAL DATA/BRAKE WEAR LIMIT CARRERA 4S WITH PCCB. If necessary, turn back the piston to its original position using the resetting fixture. Fit new vibration dampers in the pistons. Remove protective film from the vibration dampers before installation. Insert the brake pads. Ensure correct brake pad quality. The brake pad quality on the front and rear axles is identical. The pad backing plates (rear side of the brake pads) must not be greased. Fit new expanding spring, new retaining pin and new retainer (safety bracket) (arrow). Refer to Fig. 8. These parts are available as a repair set and must be "renewed" each time the pads are changed.

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5 Page 5 of 5 Fig. 8: Fitting New Expanding Spring, Retaining Pin And Retainer Insert the warning contact wire and warning contacts. Firmly press the brake pedal several times with the vehicle stationary so that the brake pads assume their fit in accordance with the operating state. Next, check and, if necessary, correct the brake fluid level. Bedding in the brake pads New brake pads require a bedding-in period of approx. 200 km. Not until then do they achieve their best friction and wear coefficient. During this period, the brakes should be subjected to full stress when travelling at high speed only in emergencies Mitchell Repair Information Co., LLC.