Boxster Project: Brake Work Checklist

by Trygve Isaacson, copyright c2000-2002

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Checklist for Replacing Brake Pads

  • Break lug bolts loose. (19mm socket.)
  • Jack up car.
  • Remove lug bolts.
  • Remove wheel.
  • Remove cotter pin. (Pliers.)
  • Remove outer wear sensor. (Tweezers.)
  • Remove retaining pin.
  • Move spring clip aside.
  • Remove inner wear sensor. (Tweezers.)
  • Separate Boxster S vibration dampers from pads. (Putty knife.)
  • Optional: Connect bleeder hose, open bleeder screw. (10mm or 3/8" wrench, bleeder hose, and bottle.)
  • Compress pistons. (Screwdriver, pliers, or spreader.)
  • Remove old pads.
  • (If replacing rotors, skip to rotors checklist below, then come back here.)
  • Insert new pads.
  • Place (new) spring clip over pads.
  • Insert (new) retaining pin. A little anti-seize paste is nice.
  • Insert (new) cotter pin.
  • Re-attach wear sensors to spring clip and re-insert into new pads.
  • Now is a convenient time to bleed this caliper.
  • If you opened the bleeder screw, close it and remove bleeder hose.
  • Replace wheel and align lug bolt holes.
  • Replace lug bolts and hand-tighten.
  • Lower car.
  • Torque lug bolts to 96 ft-lbs. (19mm socket and torque wrench.)
  • Press brake pedal a couple of times.
  • Check brake fluid reservoir level.

Checklist for Replacing Brake Rotors

  • (Remove the pads as per the pads checklist above.)
  • Detach brake line attachment bracket. (10mm wrench.)
  • Remove caliper bolts. (10mm hex head.)
  • Remove caliper, rest it on something in wheel well.
  • Loosen rotor attachment screws. (Philips head impact driver.)
  • Remove rotor attachment screws. (Philips head screwdriver.)
  • Remove old rotor.
  • Put anti-seize paste on rotor's hub contact area.
  • Place new rotor on hub, secure with rotor attachment screws.
  • Inspect piston seals.
  • Re-attach caliper with new caliper bolts. (10mm hex head.)
  • Torque caliper bolts to 63 ft-lbs. (10mm hex head and torque wrench.)
  • Re-attach brake line attachment bracket. (10mm wrench.)
  • (Continue with the rest of the pads checklist above.)

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