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Old 04-28-2008, 07:50 AM   #1
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Rebuilding calipers

Due to a warped rotor, I'm going to rebuild my front calipers while I'm in there swapping out the warped rotor for the new one.

Porsche only sells the dust boot, not the all-important pressure seal, but this company has them.

http://www.zeckhausen.com/Brembo/Consumables.htm#Rebuild

Scroll to the bottom of this page for their toll free number. They're located in NJ.

BTW, if you find that your high mileage 2.5 boxster needs a caliper rebuilt, then ask for the proper sized kits. Your calipers are four piston Brembos, and the pistons in the leading side of the caliper are slightly different in size from the pistons in the trailing side.

Ask for one 36mm kit and one 40mm kit PER WHEEL.

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Last edited by RandallNeighbour; 04-28-2008 at 07:53 AM.
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Old 04-28-2008, 08:11 AM   #2
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i feel real bad for you randall. ive only had to clean my MAF once in the 2 years/30K miles ive owned my 99 boxster with 95K miles on it. i would have jumped ship and found a different one by now if it was always needing repairs. do you know how much you have put into it so far?
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Old 04-28-2008, 08:39 AM   #3
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Splitting out repairs from mods and enhancements, I'd say about $4000 so far. The list of stuff that required replacement is long:

Rear struts (one was bent from a previous owner's spinout into a curb)
Oil filler tube
coolant overflow tank
Transmission
Control Arms (2)
Instrument Cluster

I know there's a lot more but I can't remember them all right now.

I'd have bailed on this particular car a long time ago, but I would be forced to go without a boxster for many years while I saved enough for a low mileage 3.4 987S... the only boxster I would want to drive at this point.
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Old 04-28-2008, 09:55 AM   #4
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randall -

when you rebuild the calipers, soak the EPDM (inner) seals in brake fluid for 30min prior to reassembly. after you remove the pistons, clean everything out with denatured alcohol & let it dry for several hours. then blow them out w/ compressed air prior to reassembly. i think i posted a DIY on the boxster racing board or even on this board somewhere. glad you found the zeckhausen link useful; they're the only people i've found who offer a reasonable deal on this stuff.

i'd found two other suppliers, but they were wanting upwards of $25 PER SEAL for the inners. i tried to have a bunch made last year but couldn't meet their minimum quantity requirement. in bulk (100+) they get pretty cheap.
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Old 04-28-2008, 12:30 PM   #5
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@insite...

Good Stuff!!... Thanks!!!

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Old 05-29-2008, 05:53 AM   #6
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Anyone have instructions and pix on how to rebuild calipers? I'm going to tackle this project as well as swapping out my warped rotor this Saturday and would like some guidance.
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