And now the front brakes...

[pfarah]

I'm getting pretty close to wrapping up this car's needs! Decided to tackle the front brakes/wheel bearings. Isn't this just a lovely hue of red? Gotta love them PO's...


Checked for proper tension on the clamping nut, of course they were both way too tight.



Dust shields to be blasted/painted:



Calipers just in wonderful shape!!


I'll finish cleaning up the spindles tomorrow although I did chase all the threaded holes this evening... More to come.

[911tracker85]

looks like the calipers I pulled off an 83 recently. PO had painted red but by the time I got to them they had rusted to the point of binding.

good luck.

[jjeffries]

Looks like there's wiring there for pad-depth sensors? My 924S doesn't have those. John

[pfarah]

John,
You are correct, there is brake wear sensor circuitry on the early 944's.

[pfarah]

Found some damage on one of the rubber brake lines:

A good time to remove them and clean up those bracket areas:

[pfarah]

Parts ready for install...

[jjeffries]

All very gratifying to follow along with, especially with how you lay things out on your clinical-grade workbench. I like!
John

[pfarah]

My wife tells me that I'm too OCD, maybe she's got a point... I actually like to lay everything out neatly so I don't spend an eternity searching for a part/tool that may be right in front of me.

[pfarah]

Spent a couple hours this evening installing the races, shields and assembled the rotor-hub. I'm hoping to finish over the next day or so but then what? I've been told earlier today that our office (local gov't) will be closed until May 4th. I need more projects! Does anyone want to bring their car over (practicing safe social distancing of course) so I won't go mad in boredom?

[pfarah]

Finished her up today:

[pfarah]

Of course, nothing goes perfectly... The brake pedal would repeatedly go to the floor when depressed after bleeding the system. I double checked for leaks (none found) as the reservoir level never dropped and no drippage anywhere so I guess the 36 year old master cylinder may have finally given up.
No leaks:



MC disassembled fo find any clues of wear/damage; I did discover some rust and the seals seemed to be worn but ok.




I also found black debris (soot) throughout the unit, although I ran through a quart of DOT 4 just yesterday and the brake system gets bled/flushed quite often (every 1-2 yrs, @5-10K miles).


New MC and cleaned up reservoir ready for install this weekend. More to come:

[pfarah]

Made great strides tonight (and corrected a dumb mistake I made the other day).
Ended up sanding and painting the booster in place while the reservoir was off. It's not perfect but much better than before.

New master cylinder installed, along with the cleaned up reservoir:


System bled and everything buttoned up!

[pfarah]

And now on to my mistake... (I'm man enough to admit when I f-up): While bleeding the system this evening, I noticed that the brake wear sensor wire didn't reach the bleeder valve cap, which also holds the wire. At first I didn't give it much thought until I realized that I had installed both front calipers on backwards! Luckily, no harm done and the units were swapped in about an hour.
Lesson learned my friends... Double, no triple check your work and if you think something is off, it probably is...

[jjeffries]

Do you think that was why you couldn't bleed?

I made my own boo-boo today, which I'll document in my thread.

Oh well! John

[pfarah]

Hey John, the system was bleeding fine, just the cap and wear sensor wire weren't lining up which made me pause and look at the before pics. Curious to what you did...

[pfarah]

Performed a test drive yesterday (@70 miles), by myself of course, and experienced no problems. Could it be that I'm done for now? we'll see...

[Stoneguy]

Had I known.......
I just upgraded and I have front and rear parts, completely rebuilt, less than 500 miles on everything. Went with Brembo upgrades and am looking to get rid of old parts.

That being said, your rebuild looks great!

[Stoneguy]

My upgrade

[pfarah]

PM'd you...

[jjeffries]

Stone,

Good for you, looks great. Fresh yelllow zinc is always fun!

John

Originally Posted by Stoneguy

My upgrade