Complete Suspension and Brake Upgrade (lots of pictures)
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Complete Suspension and Brake Upgrade (lots of pictures)
I’ve just finished a complete upgrade and overhaul of the suspension and brakes on my 2003 996TT. I’ve included a parts list for all of the suspension components used.
Hubs were replaced with 997. Of course, replacing the hubs required new wheel bearings as well. Before putting in the new hubs and bearings I bead-blasted the uprights and painted them.
Coilovers are Ohlins Road & Track units. Front upper strut mounts are from JRZ, and rear upper shock mounts are from Rennline. I had custom upper spring perches machined for both front and rear. Rennline includes integrated nut/bushings for the rear upper mounts in M12x1.0 and M12x1.5, but unfortunately the Ohlins are M12x1.25 so these had to be reworked for my application.
Front and rear lower control arms are Porsche Motorsports 997 components. These have forged aluminum bodies, solid thrust bushings with caster adjustment, use shims for adjusting camber, and monoball inner bearings. Fronts are the style with the OEM outer ball joints, while the rears have the upgraded re-buildable outer ball joint and high-strength pin as used on the RSR.
Rear upper control arms I put together myself with threaded aluminum tubes from AFCO, NMB aerospace rod-ends, and custom-made 17-4 stainless bushings.
Rear toe-control arms are made by Pro-Series Fabrication and are pinch-bolt style machined from 7075-T6 aluminum. NMB rod-ends are used again, and the outer pin is from Porsche Motorsports. Bump-steer can be adjusted by using spacers. All of the rod-ends received dust boots.
New Porsche hardware was used for all connections, and eccentric lock-out plates were used for the rear toe-control arms and lower control arms. While I was at it I modified the front radiator brackets for tire clearance.
Brakes are Brembo 2-piece 72-vane 997TT disc assemblies in 350x34mm front and 350x28mm rear sizes. Calipers are 991 PCCB units, 6-piston front and 4-piston rear with Pagid pads. Brake lines were custom made to my specs by Goodridge. Air guides (not shown) are from the 997 GT3.
Hubs were replaced with 997. Of course, replacing the hubs required new wheel bearings as well. Before putting in the new hubs and bearings I bead-blasted the uprights and painted them.
Coilovers are Ohlins Road & Track units. Front upper strut mounts are from JRZ, and rear upper shock mounts are from Rennline. I had custom upper spring perches machined for both front and rear. Rennline includes integrated nut/bushings for the rear upper mounts in M12x1.0 and M12x1.5, but unfortunately the Ohlins are M12x1.25 so these had to be reworked for my application.
Front and rear lower control arms are Porsche Motorsports 997 components. These have forged aluminum bodies, solid thrust bushings with caster adjustment, use shims for adjusting camber, and monoball inner bearings. Fronts are the style with the OEM outer ball joints, while the rears have the upgraded re-buildable outer ball joint and high-strength pin as used on the RSR.
Rear upper control arms I put together myself with threaded aluminum tubes from AFCO, NMB aerospace rod-ends, and custom-made 17-4 stainless bushings.
Rear toe-control arms are made by Pro-Series Fabrication and are pinch-bolt style machined from 7075-T6 aluminum. NMB rod-ends are used again, and the outer pin is from Porsche Motorsports. Bump-steer can be adjusted by using spacers. All of the rod-ends received dust boots.
New Porsche hardware was used for all connections, and eccentric lock-out plates were used for the rear toe-control arms and lower control arms. While I was at it I modified the front radiator brackets for tire clearance.
Brakes are Brembo 2-piece 72-vane 997TT disc assemblies in 350x34mm front and 350x28mm rear sizes. Calipers are 991 PCCB units, 6-piston front and 4-piston rear with Pagid pads. Brake lines were custom made to my specs by Goodridge. Air guides (not shown) are from the 997 GT3.
Last edited by msv; Oct 7, 2017 at 04:10 PM.
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Originally Posted by msv
I’Brake lines were custom made to my specs by Goodridge. Air guides (not shown) are from the 997 GT3.
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Very nice. I especially like the brakes. The double bridge calipers look stout, should have nice pedal feel and stopping power. Great attention to detail. When do we get a road test report?
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996 turbo hubs were superseded by the 997 parts. It's debatable if they are any stronger or not. They certainly use a more sophisticated forging.
Last edited by msv; Oct 7, 2017 at 10:56 PM.
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Nice conversion! One question: How does 997's wheel carriers/hubs go together with 996's ABS/wheel speed sensors? Any pics of hubs from behind with sensors installed?
(On 997 C2S's hubs the sensor model and placement is totally different from 996's...)
(On 997 C2S's hubs the sensor model and placement is totally different from 996's...)
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Only the hubs are updated. The carriers are my originals that I reconditioned.
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OK, I see, I should have read the text with thought...and 996 AWD front wheel carriers look a bit similar to 997's...
