And Now The Brakes...

[pfarah]

I guess it's time to rebuild the rear calipers and I might as well take a peak at the rear parking brakes since it's one of the last systems not addressed since my ownership. Here's what I found:



Not too hatefully but it looks like the outer axle seals allowed some grease to escape so I did spend a fair amount of time cleaning...

[pfarah]

BTW: Removing the 36mm castle nut was a piece of cake, just a crow bar and my old 1/2" electric impact gun.


Re-installing the nut to 350 ft/lbs... Well, I haven't got to that yet.

[pfarah]

I figure I'll replace all the hardware/springs while it's all apart.

[pfarah]

The one issue I've run across is that the outer axle sleeve (shim?) is NLA; the driver's side is a little buggered up so I'll attempt to clean it up with some 1000/1500 emory paper. Also, I noticed there's a pretty thin O-ring on the hub (never would have found it without reading the manual).

[jjeffries]

Patrick, that's pretty crusty in there! Those springs and linkage parts might clean up OK? John

[pfarah]

Hey John,
The springs appear to be in working order but I'm going to replace most everything in there anyway. The bow is in good shape but new pins/pin locks will also be ordered. It looks like these assemblies were never touched, however; I did replace the pads about 4 years ago as there's still plenty of meat on them.

[911tracker85]

here is what I found lurking behind that piston and destroyed dust cover in the last two brake rebuilds of older 944s. both sets cleaned up nicely but took a bit of 'elbow grease'.....

good luck.

[jjeffries]

Bob, that looks like something from a space/horror movie. John

[pfarah]

Funky indeed.

[911tracker85]

yea it was gross....

after having to rebuild the front calipers for a guy because they had rusted together and no longer sliding. found this in the front calipers.

when I suggested I rebuild the rear calipers he asked if it was necessary. but then proceeds to tell me about the maritini racing stripes he planned to have painted on the car. he relented and I rebuilt them and yes they needed it too.

in both cases I suspect I am the first to pull those calipers apart.

[OK-944]

Yup...can't see those stripes from the drivers seat - but I sure as heck can feel that tree I just plowed into because my brakes failed! Jeeesh! Mechanicals First - Always!

[pfarah]

Might as well keep going while I'm in there, right?
The bearings look and feel good but let's just replace them anyway. Who knows if/when that's been done.

[pfarah]

Been waiting on parts which came over the weekend. Also, I had some parts cleaned (glass bead/walnut shell blasted)and painted if needed.

[pfarah]

Assembled parking brake assemblies this afternoon:

[pfarah]

I do have a question though...
Does anyone know the rear axle seal thickness? The old inner seals measured at 8.00mm while the replacements are 9.80mm. The outer seals also measure at 9.80mm. According to the shop manual, both inner and outer seals are the same part number. Thanks for any insight.

Old:

New:

[pfarah]

After conducting a bit more research, it appears that the wrong (thinner) seal was installed along the inner axle bearing. The part number ended in "G" where the correct seal ends in "H". Another PO correction!

[pfarah]

Found an easy way to press in the inner bearing without removing the muffler or banging away with the ole' hammer. Harbor Freight's seal kit and some threaded rod to the rescue.

[pfarah]

I've used Timken Red Premium Wheel Bearing Grease for many years with great results.

[jjeffries]

Great stuff you're doing there Patrick.

John

[pfarah]

Thanks! Re-installing the parking brake hardware is being a pain. Time to stop for the night and leave it for a while...