Brake Pads – Checking Pad Thickness and Replacing Pads

Overview

This guide explains how to check the thickness of brake pads and replace them on a Porsche 944 with a 16v engine. Regularly inspecting and replacing brake pads is crucial for safe braking performance. Worn pads can reduce stopping power and damage the rotors, so Porsche recommends checking them every 15,000 miles (24,000 km) or whenever the wheels are off.

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Tools Required

• Jack stands
• 19mm socket and ratchet/breaker bar (preferably 1/2 inch drive)
• Metric wrench set
• Metric socket set
• Bailing wire or shock cords
• Bearing grease, petroleum jelly, or anti-squeal pads
• Large channel lock pliers
• Needle nose pliers
• Lineman’s pliers
• Turkey baster or vacuum pump brake bleeder
• Rags for cleaning brakes
• Small pry bar or large flat-tip screwdriver
• Brake piston compressor (optional)

Parts Required

• Brake pads for Porsche 944  – 944 351 951 06
• Wear indicators (if replacing pads at 2mm or if activated) – 944 612 211 00

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Bleeding the Brakes

Step-by-Step Procedure

Step 1: Prepare the Vehicle

1. Using a 19mm socket and ratchet or breaker bar, loosen the lug nuts on the wheels where brake pads will be checked or replaced by two turns.
2. Lift the car and secure it on jack stands.
3. Remove the wheels to access the brake calipers.

Step 2: Check Brake Pad Thickness

4. Locate the brake pads within the caliper. You’ll see the pad material against the rotor.
5. Measure the thickness of the pad material using a ruler or caliper. The minimum thickness is 2mm, but Porsche recommends replacing pads at 2.5mm for optimal performance.
6. If pads are at or below 2mm, or if the wear indicator light is on, plan to replace them and the wear indicators.

Step 3: Remove the Old Brake Pads

7. Using channel lock pliers, compress the spring clip in the middle of the caliper and push it inward toward the rotor to disengage it from the support.
8. Move the clip support away from the top of the clip and pivot the clip outward, away from the caliper.
9. Lift the wear indicator wire from the groove in the caliper and gently remove it from the brake pad plate. Be careful, as the clips break easily.
10. Insert a small pry bar or large flat-tip screwdriver between the old brake pad and the caliper piston. Press the piston outward to make room for new pads. Avoid pressing against the rotor—use the old pad if possible since it’s being replaced.
11. Watch the brake fluid reservoir level as you press the piston. If it gets too high, use a turkey baster or vacuum pump brake bleeder to remove some fluid and prevent overflow.
12. Using lineman’s pliers or needle nose pliers, remove the old inner and outer brake pads from the caliper.

Step 4: Clean and Prepare the Caliper

13. Use clean rags and brake cleaner to wipe down the caliper and rotor, removing dust and debris.

Step 5: Install the New Brake Pads

14. Apply a thin layer of bearing grease, petroleum jelly, or anti-squeal compound to the back of the new brake pads (944 351 951 06) where they contact the caliper piston.
15. Insert the new brake pads into the caliper slots.
16. If replacing wear indicators, install new ones (944 612 211 00) by securing the wire into the caliper groove and attaching the clip to the pad.
17. Pivot the spring clip back toward the rotor.
18. Using channel lock pliers, compress the spring clip in the middle and push it into position against the rotor.
19. While holding the spring clip with the pliers, move the clip support into place at the top of the clip to lock it in.

Step 6: Reassemble and Test

20. Reinstall the wheels and tighten the lug nuts to 130 Nm (96 ft-lbs) using a 19mm socket.
21. Lower the car off the jack stands.
22. Engage the parking brake and consider using wheel chocks for safety.
23. Check the brake fluid reservoir level and add fluid if needed.
24. Start the engine and pump the brake pedal until it feels firm at its normal height. Do not drive until this is achieved.
25. Recheck the brake fluid level after pumping.
26. If the pedal feels spongy, follow this link to ensure this step – Bleeding the Brakes – of the process is followed accurately.
27. Take the car for a short drive of about 5 miles (8 km), making gentle stops at first, then progressively harder ones to seat the new pads. A burning smell or light smoke is normal during this break-in period.

Post Procedure Checklist

• Ensure the brake pedal feels firm and returns to its normal height.
• Check the brake fluid reservoir level and top off if necessary.
• Inspect the wheels for any signs of brake drag or uneven wear after the test drive.
• Confirm no warning lights (e.g., brake wear indicator) are illuminated on the dash.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• Youtube