Bizarre brake situation, how can this happen?

[Boxstard]

Originally Posted by unpolire

I found wheel bolts all over the freeway and roadside when I went to retrieve the car with a flatbed.

When that happened on my VW bug, I found 3 lug bolts still captured behind the hub cap but one escaped and could not find it on the road…

[old911doc]

Before you order your bearings, be aware that the S version uses a different bearing, and half shaft, than the standard model Box.

What a mess of a situation you had. I would think that a diligent mechanic would wiggle the hub to check for bearing play, sort of reflexively, while replacing discs and pads. That simple brake service is the first thing that instructors have novices do, well before letting a novice get hold of a spark plug socket.
And, to my mind, a Boxster is a relatively easy car to care for. Lemme tellya about a Lotus Elan…

[old911doc]

Oh, and one last thing, PLP is right, the little setscrews are more a convenience than a necessity, but I would suggest you should indeed use them, so that before you put the tire on you can rotate the disc to check that it is indeed not warped, and so you can check the bearing integrity (!!!). That said, they can certainly cause unnecessary grief by rusting in place, getting the head stripped, etc. So, use them, but with plenty of anti-seize paste, and tighten just ‘finger tight’. The heavy forces of braking are taken by the wheel lug bolts, or on studs ( in the case of…old 911’s…).

[Boxstard]

Originally Posted by old911doc

Oh, and one last thing, PLP is right, the little setscrews are more a convenience than a necessity, but I would suggest you should indeed use them, so that before you put the tire on you can rotate the disc to check that it is indeed not warped, and so you can check the bearing integrity (!!!). That said, they can certainly cause unnecessary grief by rusting in place, getting the head stripped, etc. So, use them, but with plenty of anti-seize paste, and tighten just ‘finger tight’. The heavy forces of braking are taken by the wheel lug bolts, or on studs ( in the case of…old 911’s…).

My impact driver is used almost exclusively for removing those little rotor set screws, works every time even when they got frozen. As noted already, they don’t bear much load so no need to be super tight and if you use anti-seize you will not have issue removing them. That said, they should not be omitted and obviously a shop who does such cannot be professional enough and trustworthy.