Porsche Brembo 996 BBK conversion

[Slideways]

Would coding for CSL bias be different than ZCP?

Pretty sure they are the same as they both got the same braking hardware.

[ca86108]

Hello Everyone,

I just purchased my e46 m3. The car came with this exact conversion. Can you all help me with the following questions? Thanks

1. Can anyone recommend some more aggressive pads for front and rear? Can you send me the direct link or part number? I feel the stock Porsche pads are kind of soft and don't stop really hard with aggressive driving.

2. I see conflicting answers to this question. Is this BBK conversion from a 996 Turbo and a Cayman S? I see some websites saying they sell the pads for with the part numbers but they say (except for Turbo models, or Except for Cayman S). If I was to go to a shop to rebuild the calipers, what car do I say these calipers and set they are from?

3. Are both the front and rear 4 pot?

Thanks for all your help

[D-O]

Hello Everyone,

I just purchased my e46 m3. The car came with this exact conversion. Can you all help me with the following questions? Thanks

1. Can anyone recommend some more aggressive pads for front and rear? Can you send me the direct link or part number? I feel the stock Porsche pads are kind of soft and don't stop really hard with aggressive driving.

2. I see conflicting answers to this question. Is this BBK conversion from a 996 Turbo and a Cayman S? I see some websites saying they sell the pads for with the part numbers but they say (except for Turbo models, or Except for Cayman S). If I was to go to a shop to rebuild the calipers, what car do I say these calipers and set they are from?

3. Are both the front and rear 4 pot?

Thanks for all your help

Welcome to the forum.

Right from the Rally Road site (most conversions are done using their kit):

Front:

Calipers used for this conversion are Front Calipers from the 1999-2004 Porsche 996 (non-turbo), the Boxster S or the Cayman S. All these calipers are made from the same Brembo casting.

The Porsche caliper part numbers for this conversion are:
996.351.425 (driver side)
996.351.426 (passenger side)

Rear:

Calipers used for this conversion are Rear Calipers from the 1999-2004 Porsche 996 (non-turbo), the Boxster S or the Cayman S. All these calipers are made from the same Brembo casting.

The Porsche caliper part numbers for this conversion are:

996.352.421 (driver side)

996.352.422 (passenger side)


Both front and rear are 4 pot.

I will leave the brake pad recommendations to others.

[Tbonem3]

Pfc z
ferodo ds2500

[robgill]

I run the following for track pads:

PFC 08 0776.08.16.44

PFC 08 0776.08.17.44

[Ramage]

I installed the front 996 calipers on my 2004 convertible yesterday.

The process was mostly straightforward, but I encountered one major challenge: the 16mm carrier bolts. There was an excessive amount of Loctite on these bolts, so I had to use heat and PB Blaster to remove them. Even after applying heat and the blaster, it was extremely difficult to break them free.

This issue was frustrating and turned what should have been a one-hour job into a three-hour endeavor. If anyone faces a similar problem, I recommend removing the discs to gain better access to the carrier, which will help you apply heat more effectively.

I used Rally Road brackets (older style that I bought back in 2013) and did not have to grind anything to achieve a good fit.

[mdefalco25]

Just getting parts ordered for the 996 calipers but currently running with ARC 8s
Front: 18x9” ET30 with 245/40-18 tires
Rear: 18x10” ET25 with 275/35-18 tires

I’ve seen a few state that a 5mm spacer will work up front but Apex suggests a minimum of 3mm gap between spokes and caliper and that an 8mm at a minimum would be needed. Anyone confirm 5mm will work?

[bavarian3]

Looking for advice here on rear 996 calipers with rallyroad brackets.

Does everyone have this tight of tolerance between the caliper body and the rotor? This doesn't seem to be enough space for heat expansion.

[I see there are some shims included with the rallyroad brackets, but I believe these are for horizontal spacing of the pins which I have no issue with.]





Also, are these supposed to hang over the brackets like this? I don't see any other way to fit these. Doesn't smell right.





Tbonem3 Arith2 heinzboehmer maupineda Obioban Nate047 D-O

[Tbonem3]

I remember having to file down part of that bolt head on a friend's 06 zcp. I personally have CM, but I'll be installing rear RR brackets on another friend's car soon.

[bavarian3]

I received a response from Rally Road. Still curious to hear others thoughts with experience with these.

"I don’t see anything wrong in the pictures. There’s variations from car to car and rotor to rotor, etc. There’s also no need for the bracket to mate with every part of the caliper mounting surface. Sure…we could have designed it that way but then it would cost $50 more with no benefit.
If the caliper is physically rubbing on the outside ring of the rotor, then I would clearance the caliper with a file. A millimeter of clearance should be enough.
If we moved the calipers further away, then the brake pads wouldn’t fit the same.
Everything looks just fine based on your pictures."

With all the work involved with retrofits, I see why BBK's cost what they do. Upon test fitting these look great however, excited to get em' running.


Tbonem3 Are you referring to the control arm balljoint bolt? No issue there.

[Tbonem3]

yes. It's a tight fit (the rotor to caliper), but no evidence of them touching.

[maupineda]

Mine does not have that little of a gap. Have the car on stands, let me take a pic

[maupineda]

I take that back, seems is a tight fit. I don’t have my feeler gages but is barely 1mm of clearance. I do not see any rubbing though.


I have more clearance to the bolt, but maybe is the photo angle on yours?



mine have about 12k of road use.

[bavarian3]

Thanks for providing the pics maupineda . I just mounted mine up and they fit fine, like yours do. No rubbing, just spooked me at first.


With that closed, this project just keeps handing me gifts as I have a new dilemma. On the Megane (Freakyparts kit) front calipers, the radial mount bolts don't thread all the way through the brackets. The provided bolts are m14x80mm socket heads. The next size up is 90mm.

I'd like opinions on whether to:
1. use 90mm bolts and trim the bolt to avoid the knuckle.
2. use 90mm bolts and shave off knuckle to accommodate bolt
3. use the 80mm bolts as is...

Edit - I was able to locate 85mm bolts on amazon of all places. Nothing on Mcmaster, belmetric or boltdepot. I think these should do the trick, they are fully threaded however.

pics: