Time for a brake job. Questions for the group.

[Robert Coats]

The “brake pad wear” indicator light came on today. It would seem my ’91 C4 needs a brake job.

My plan is to get the rotors off and resurfaced, install new pads, then take it to a shop (that has a Bosch Hammer) and get the entire hydraulic system flushed, filled and bled.

Before I begin, questions for the group:

(1) Curious, but how does this indicator/sensor work? How does it “know” the pads are worn?

(2) I’ve done dozens of brake jobs on other cars, but is there anything out of the ordinary about the 964 (C4)? Specifically:

(a) Can I get the calipers off the rotors and the rotors off the car without disconnecting any brake lines?

(b) Are the wheel bearings sealed or open (and require repacking with grease)?

(c) What else should I look for while doing this job?

(3) Any other hints or suggestions when doing a brake job on a C4?

(4) Finally, what brake pads do you like for normal street driving? OEM or is there a better answer aftermarket?

[Britwrench]

The brake sensor has a wire running through it, when the pad wears enough, the sensor touches and is then worn through by the brake disc and the circuit is broken; the light then comes on.

Do not resurface the discs; either they are ok and cen be re-used or they are worn/grooved/warped and should be replaced. New ones must be thoroughly cleaned before installing.

You do not have to disconnect the hydraulics to replace the discs, be careful that you do not strip out the allen heads of the rear caliper fixing bolts.

The wheel bearings are sealed and cannot be re-packed.

We use stock Pagid pads.

Make sure the calipers are clean and the pads slide easily. Some 964 have anti-squeal dampers, they can be re-used if you seperate the pad from the damper with a scraper and then re-glue the damper back onto the pad. I would replace them if there is any doubt about their condition.

You do not need a "hammer' to only bleed the brakes, thw 4wd system is the only part that requires the tool. The brake system can be bled using a power or vacuum bleeder. The boost system in the front of the car should be bled as well.

Check the date of the ABS relays, if before 1991 they should be replaced as the power pump relay can stick and keep the pump running, which burns it out...pump replacement is $2000