Expensive caliper rebuild! grrr

[bakerloid]

So, my S2 was recently showing definite signs of plate lift on the rear calipers (not a problem, reasonably easy fix, and 'hey why not throw new seals and boots in there at same time'), whilst these were off I decided to overhaul the fronts too, just for the sake of it more than anything as the system was fully bled etc etc.

Long story, but essentially I'm further involved with the fronts now, definitely past the 'point of no return' with regards to having to replace dust seals all round!

Pain in the arse bit is that I have the slightly older 44/36mm piston calipers using the 'scraper ring' style dust covers, as opposed to regular 'boot' style ones. Unfortunately for me, I'm struggling to find these scraper rings individually from anywhere else other than as part of the rebuild kits that Porsche provide, which include piston, bore seal and dust seal. (I have managed to find two of the 44mm seals from somewhere, but that's all). If I go to Porsche on this one, I'll be looking at £31 for each 44mm piston, and £40 for each 36mm piston! So, that's around £284 just for the front set of calipers! Gulp []

Has anyone on here been in a similar position before, and other than buying new calipers (I.e the ones with dust boots), do you know of anywhere that I can source these scraper rings from individually?

Just writing this before I get up for work, so I don't have all the details in front of me, but when I get into work I'll add all the relevant part numbers, brembo part numbers, all the places I've tried so far, and some pics that may help.

Thanks in advance - it would be a great resource to know where we can get these bits from a little cheaper than mentioned above, as I'm sure others will be in the same boat as me sometime...

Cheers, keep smiling! []

James

 

[os951]

I suppose S2 should have newer style dust covers, like all 1987 and newer 944 models have.

 

[peanut]

good luck James. I need to do the same myself shortly .

There was an S2 refurbished rear caliper on ebay last week for £89.00 but to be honest its probably best doing the work yourself so you know its been done to a good standard.

 

[bakerloid]

Olli- you're absolutely correct, most S2s should have the newer style dust covers. The callipers off my car are actually slightly earlier Turbo ones, I believe. They were probably a diy upgrade by the previous owner. The calipers themselves are in great condition, its just the rarety of these seals thats going to come and bite me!

Nick - as you say, I would rather do the work to them all myself, so I can be sure its done properly...or atleast in a state that I have no one else to blame, if you see what I mean. This could be beneficial to you as well then, hopefully we'll be able to get some results!

 

[bakerloid]

Here are some pictures of the dust seals (scraper rings) I'm after - both are of the 44mm one, from different angles.

They do have some Brembo part numbers printed on them:
44mm has 204513 82 10
36mm has 204513 72 10

The Porsche part numbers for the repair kits are as follows:

928 351 919 01 repair kit for 44mm
951 351 919 01 repair kit for 36mm

So far I've tried the following people (for the dust seals individually), to no avail:

Brakes International
Promax
Bigg Red
Brake Parts Uk
Race Pads
Mode Performance (these lot have the two 44mm seals kicking around, which I've since bought)

 

[barks944]

Is this a problem with the rears as well as the fronts?

 

[944Turbo]

Have got similar (assuming those are rubber - hard to tell from the pic and have only seen the later brakes) from here http://www.raceparts.co.uk/products/brakes_and_brake_components.asp?section=Girling+Caliper+Seals
doesn't look like they list the right sizes but might be worth a call,
Tony

 

[peanut]

were these calipers used on Mercs of the period I wonder ?
Also the 968 used the same calipers I believe ?

 

[bakerloid]

Cheers for all the suggestions guys - I did try calling RaceParts, but unfortunately they had never seen these types of dust seals either ...doh! So, thats another one off the list.

Had a bit of a google around Mercs using these calipers too, but nothing obvious coming up there either.

I should be getting the calipers back from my powder coating guy early next week - will see if there are any identifying part numbers for them, if so I may have better luck with my googling from that angle. Fingers crossed []

 

[sulzeruk]

Seals are only available from Porsche, I tried to get some before and nobody had them at all or would make them due to the metal backing. It looks like you need to bite the bullet or buy a set of calipers. I probably have a full set of late style calipers needing refurb here. Would take your old ones as a part ex as they are good for spares. Let me know and I will have a dig through tomorrow at the garage or give me a ring on 07515 899 500 if you want to discuss,
Alasdair

 

[bakerloid]

Hi Alasdair,

I know what you mean, I think I've almost resigned myself to the fact I'll be needing to bite the bullet one way or another on this one!

Starting again with some different calipers would be a bit of a shame as my current ones have been cleaned up, shot blasted and powder coated already...[] However, there is a lot of sense in your suggestion! I will do some calculations, see what my options are and possibly give you a bell later on, if that's ok?

In the meantime, do you know if the ones you have are definitely the 44/36mm type (MO30)?

Cheers,

James

 

[peanut]

204513 82 10

excuse my ignorance chaps but if the the early and late type piston seals only fit their respective pistons, why can't you change your early pistons for late ones ? surely the pistons are the same bore size and fit ?
i'm following this thread with some interest as I urgently need to replace my entire braking system on my S2

Apparently the brake components are the same for the 928S4, 944S2 , 944 TurboS are they also the same for the 968 models ?
If so you can get refurb kits for 968 calipers (MO30 & non MO30) pistons and seal kits here http://www.porscheshop.co.uk/acatalog/porsche_968_brake_components.html

 

[bakerloid]

I do see what you're saying, however unfortunately the dust seals are not interchangable between the early and late style calipers. The more common dust boot has a metal ring embedded within the outer edge of the rubber. When installing into a later style caliper, this metal ring is pushed into a circular recess that surrounds the piston bore. On the earlier style caliper, which I have, there is no circular recess around the piston bore. Instead we have a recess purely around the top inner edge of the piston bore. The dust seals in question (scraper ring) is an exposed metal ring with the rubber seal being on the inside (as in the pictures above). This metal ring simply pushes into the recess that is situated at the inner top edge of the bore, and is held there purely by being a snug fit. Hope that makes sense...? It's quite a tricky thing to describe, If you see it yourself you'll see exactly what I mean.

The main difference with these two types of caliper is that the seal on the earlier type keeps dust out of the bore by being flush with the edge of the piston as it moves back and forth, whereas the later type is engineered so that the seal grips a recess in the end of the piston, and the rubber 'boot' section stretches and moves as the piston goes back and forth. Probably worth peering inside yours and checking what you have. If its the dust boot arrangement, you'll be fine and costs won't be crazy.. However, if It's scraper rings, save those pennies! []

Good point though, and definitely worth the mention. I really wish I could do what you've suggested. I reeeeeally do![]