Questions on rebuilding 996 C2 calipers

[polizei]

Hey guys,

I'm considering having my set of 996 c2 calipers powder coated before installing. I have a few questions before jumping into it:

1. What's the process to remove the pistons from the calipers? Any special tools needed or common mistakes to be aware of?

2. What parts do i need to replace the seals? Just these dust covers? Porsche 996 Brake Hydraulics - Page 3. The fronts have 40 and 36 mm pistons, and reads have 30 and 28 mm.

3. What's the process for reinstalling the pistons? Should the pistons or inside of the seals be greased?

4. Anything else?

Thanks as always!

[DRACO A5OG]

It should be the similar process as the tech adticle.

1. air compressor to blow the hardline connector, make sure one side is clamped and only allow half of the piston to come out. Be slow and methodical.

2. I would call and talk to a rep, they can better direct you on the correct size.

3. Brake Fluid is all the lube you need, just do your best to keep the install clean so you will minimize the dirt and debris into the system.

4. Read the tech article twice and have fun with it.

Note, if you suspect the pistons are stuck, leave the caliper on the car and press it out using the brake system. Just make sure you block the pistons from going all the way out.

Depress the brake pedal about 2 inches with a 2X4 to insure no air goes back up the system prior to disconnecting the lines.

When you are ready, do the 2 man team bleed. place a block of wood behind the pedal so it will not fall all the way to the ground to save your Master Cylinder.

Tell your helper to press hard and when you release the valve to chase the pedal fast do not allow it to go down without force.

Also to make certain all the air is coming out. The drain hose attached to the valve must be going upward to allow the air to flow up from the valve.

Bleed at least 3 full times. Couple of days later as the system settles do it again to get all or most of the air out.

I would get two litres of fluid for the job.

Jim

Just did mine recently on my 3.2 and helped a buddy's 87

[polizei]

Draco - Thanks for the great write up. I'm working with a pro on the reinstall to ensure that I don't screw anything up!

I'm certain that I've got the caliper piston sizes correct, but I'd like to verify exactly which seals I need to replace for a rebuild. Do I only need the Dust Covers sold here on Pelican or are there any other parts?

Thank you,
Andy

[polizei]

Bump.

I got the pistons out last night, but it was very difficult to get them out without SHOOTING them out. Also, it was tough getting the dust boots off the pistons. Any suggestions on that?

Does anyone know if the Dust Covers sold here on Pelican include the Pressure Seals as well?