Please help on alloy S brakes

Hi,
I am trying to repair the alloy S calipers on my 69' 911, since the pistons were kind of stuck, I tried to open a cover on the back side. However, the factory repair manual indicates that the screws on that cover plate should not be loosend and the plate should never be removed, can anybody tell me why?

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They probably don't want you to disassemble them because they will probably leak. If your piston is frozen, try using a C-Clamp to compress it. I have a straight jawed one I purchased from sears and use it everytime I change my pads. Works great. The other alternative is to use a fork for removing Tie Rod Ends. Wedge this in between the piston and housing and get a tapered chisel and tap it in a little at a time. That should free up the piston.

I wouldn't disassemble the unit unless you are certain it can be reassembled to manufacturers specs.

Steve.

Here's a good question: what are the steps involved with doing your own brakes? I know you have to pull the pin out, and then the pads, to replace them. But what else does one do when "doing" the brakes on a 911?

Forgive the pretty basic question.


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Mark Szabo
1986 911 Targa 3.2

Dude,I just reinstalled my rebuilt Alloy "S" calipers and they work great. Definately do not remove that back plate, although I don't think it's curtains for your caliper if you've already done so. If your trying to remove a piston, compressed air is the way to go. Stuff a rag in between the pistons so they don't go flying and put a moderate amount of compressed air into the hard brake line entering the calipers. It doesn't take much, I used an air gun just held to the hard line and they popped right out. Once I had my pistons out it was obvious that I needed fresh ones, lots of corrosion. I didn't feel qualified to rebuild them myself so I sent them to the folks at G&W in Waynesboro, Va. For a very reasonable labor charge ($145)they dissassembled them, thuroughly cleaned them, reassembled them with stainless pistons (Automotion or AJ USA for about $135 per side)and all new seals and then indexed the pistons correctly (very important). They look/work great and with the stainless pistons they should be a very long term fix. Along with a set of Carbon Kevlar .485CF brake pads, it brakes astonishingly better. I know after doing the math you're thinking yikes, that's 450-500 bucks in parts and labor, but it's worth the bucks to have a permanant fix.

Hi all,
Thanks for the help, but the pistons on my brake were completely seized!(I haven't driven the car for the past 4 yrs.) I put in about 100psi of compressed air and the pistons won't even move. Later I used c-clamps to force them in until they moved some then use compressed air, they finally came out!
I have just cleaned them and ready to put in new ss pistons and new seals, thanks again!
Chien