Help, I can't get the Caliper on my new Rotors

Miscou · 01-26-2013, 12:51 PM

I've purchased the Pelican Brake kit for my 2000 996. The kit includes new rotors, pads, and all the hardware. I had no trouble getting anythings apart and mounting the new rotors. When I tried to remount the calipers, they would not fit over the new rotors. The problem seems to be the four pins (two on each caliper) that are located close to the center of the wheel. These pins go through the caliper and I am wondering if they are supposed to move in and out. The new rotor width is wider than the gap between the two pins by four to five millimeters. Has anyone run into this problem before?

JFP in PA · 01:45 PM

ThThe two lower “pins” do not move, it sounds more like you do not have the pistons retracted enough for the pads to clear. Check the front brake diagram in this file:

http://www.porsche.com/all/media/pdf/originalparts/usa/996_USA_KATALOG.pdf

Miscou · 01-26-2013, 01:58 PM

JFP, thanks for the reply. The pistons are not the problem, they are fully retracted. The problem is the 4mm clearance difference between the width of the new rotor and the gap between what appears to be fixed pins on the calipers. I was not able to find these pins in the Porsche parts manual when I looked fro them. When I viewed the DIY in the Tech Center, the pins appear in all of the photos. So, I'm not really sure what these pins are called, or if they are supposed to move.

JFP in PA · 01-26-2013, 02:38 PM

As I said, the two lower (towards the center of the rotor) "pins" do not move; they are held in place by small roll pins inserted from the bottom side of the caliper. Their purpose is to hold the bottoms of the pads so they do not try to rotate inside the caliper under braking. When the small roll pin comes out, this is what happens:

And this is the roll pin that retains them:

So in normal use, they do not move.

Miscou · 01-27-2013, 07:06 AM

JFP: Thanks again for the help. Finally got to the bottom of this. Looks like I ordered the Turbo Kit by mistake (off by one number , 01 v 02). So, I have all the parts for the turbo brake set up, not the standard 996. Really appreciate the help. Your input allowed to to recognize my mistake much faster. ........Chris

JFP in PA · 01-27-2013, 07:14 AM

The right parts always helps...................