Installing Monoblock Calipers - A Few Quick Questions

[jyl]

I've revived my "cosmetic brake upgrade" project. Boxster monoblocks and Zimmerman drilled rotors on the front, keeping the stock Carrera rear calipers and adding drilled rotors on that end.

Yes, it is just for looks. Anyway, I have a couple of questions.

First, on the Boxster caliper, is the larger piston supposed to be ahead of the smaller piston, or vice-versa? (By "ahead" I mean a spot on the rotor passes under the larger piston first, then under the smaller piston, when the car is moving forward.)

Second, is it necessary to use some special grease on the pistons and bores? I've read "yes it is", and I've read "no just use clean brake fluid".

Third, is powder-coating better than painting, and why/how? The color will be flat or matte black. My main concern is that a painted caliper might look grungy after a few years; I wonder if powder-coating will be more durable. On the other hand, I assume painting is cheaper.

Fourth, what brake fluid and pad recommendations for street driving?

Fifth, I don't think the pad wear indicator sensors on my Carrera fit the Boxster calipers? Correct?

Will replace flexible lines with stock rubber from PP, not changing master cylinder or proportioning valve.

Thanks!

[KTL]

The smaller piston is the leading and the larger piston is the trailing.

The grease is typically a synthetic grease like this Permatex stuff.

Permatex Ultra Disc Brake Caliper Grease

Powdercoating is typically more durable than paint. Especially in resisting chipping. Seems to be more solvent-resistant too.

I like Valvoline SynPower fluid. It's cheap and almost comparable to the more popular (and more expensive) ATE Blue, Gold stuff. For only street driving, I put the Castrol LMA stuff in my other cars. Pads are tough one. Popular street pads seem to be Pagid Blue, Axxis Metalmaster, Performance Friction Z-rated, Mintex,

Dunno about the wear sensors. Not at all familiar with Boxster brakes. Maybe you can get the Boxster sensors and they happen to use the same pigtail connection as the Carrera sensor? The pad you choose may not have a provision for the wear sensors. Sometimes they don't. You don't absolutely need them. But they're good to have instead of finding out you need new pads by feeling the pad backing plate scraping the rotor!

[Todd Simpson]

Ha! I just put 964 calipers on my car and all 4 are upside down in terms of piston orientation...I even moved the bleed lines to mount them this way.

Smaller piston first...smaller piston first...

"Honey...remember that big project I spent all weekend in the garage for that I said was finished?..."

[jyl]

As far as I can tell from the orientation of the bleeders when I got this set of monoblocks (used), they were on "upside down" with large piston first. Glad I asked here.

Going to powder coat. Found a place in Oakland that will charge $75 for four calipers.

The monoblocks came with a set of new pads, never installed. No idea what make, but given the price of new pads I will try these, regardless of lacking the sensor.

Yikes, brake hoses are more expensive than I would have thought. $72 for a complete set.

[RallyJon]

Why not just swap the crossover tube and bleed fittings end for end? It won't work very well bleeding from the bottom of the caliper.

[Jeff Alton]

When you swap the crossover tubes and bleeders you might have to bend the tube a wee bit to aid in wheel clearance. Real easy, just be aware to check before you drive away!

Jeff

[JeremyD]

and br prepared to use heat when moving the crossover tubes - I think that was the hardest part of my brake job.