Checking the Brake System – 2.5L NA

Overview

This procedure outlines how to inspect the brake system on your Porsche 944 (8-valve engine configuartion) to ensure safe operation. Regular checks of the brake pads, calipers, hoses, and parking brake are critical for preventive maintenance. For 1984 and later models (both pre-1985.5 and 1985.5 onwards), a dashboard wear indicator light signals when brake pads are worn, but this system isn’t fully reliable due to potential damage. Check the brake system every 15,000 miles (24,000 km) or whenever the wheels are removed for other maintenance.

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Tools Required

• Metric wrench set (sizes including 10mm (3/8 inch), 13mm (1/2 inch), etc.)
• Metric socket set (sizes including 10mm (3/8 inch), 13mm (1/2 inch), etc.)
• Jack stands
• Floor jack
• Measuring tool (caliper or ruler for 2mm (5/64 inch) and 2.5mm (3/32 inch) measurements)

Parts Required

• Brake pads (e.g., 944 351 951 00 for front, 944 352 951 00 for rear), if replacement is needed
• Parking brake pads (e.g., 928 352 951 02), if replacement is needed

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Parking Brake Adjustment

Step-by-Step Procedure

Step 1: Prepare the Vehicle

1. Park the vehicle on a flat surface and engage the parking brake.
2. Use a floor jack to lift the vehicle and secure it on jack stands at all four corners. Ensure the vehicle is stable before proceeding.
3. Remove all four wheels using a metric wrench or socket (typically 19mm (3/4 inch) for lug nuts).

Step 2: Inspect Front and Rear Brake Pads

4. Locate the brake caliper on each wheel. Look through the opening in the caliper to view the brake pad and rotor.
5. Measure the brake pad lining thickness (the distance between the metal backing plate and the rotor surface) using a caliper or ruler.

– Aim for a minimum thickness of 2.5mm (3/32 inch). If the thickness is 2mm (5/64 inch) or less, replace the brake pads (e.g., 944 351 951 00 for front, 944 352 951 00 for rear).

6. If measuring is difficult, remove the brake pads from the caliper (using a metric wrench or socket, typically 13mm (1/2 inch)) and measure the lining thickness directly.

Step 3: Inspect Brake Components

7. Check the brake calipers, hoses, and fittings for leaks, cracks, or damage. Replace any faulty components as needed.

Step 4: Inspect Parking Brake

8. Move the vehicle to a steep hill and place the transmission in neutral.
9. Apply the parking brake and check if it holds the vehicle stationary.

– If the parking brake does not hold, adjust it by following this link to ensure this step – Parking Brake Adjustment – is followed accurately.

– If adjustment does not resolve the issue, remove the rear rotors and inspect the parking brake pads (e.g., 928 352 951 02). Replace if worn or damaged.

Post Procedure Checklist

• Verify all wheels are securely reinstalled with lug nuts tightened to 130 Nm (96 ft-lbs).
• Check for any brake fluid leaks around calipers, hoses, and fittings.
• Confirm the parking brake holds the vehicle on a hill after adjustment (if performed).
• Test drive the vehicle for 5 miles (8 km) to ensure proper brake operation and no unusual noises.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manuals
• YouTube