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Discussion Starter #1
Hi All,

First post on here but have used the forum for quite a few years for help and info on my cars, which was a 986 for 6 years and now a 987 for nearly 2 years.
I have done numerous jobs on my cars before, brake pads, AOS, radiators, spark plug change etc and without the help of forums like this I wouldn’t have been so confident!

A few days ago on the way to work in the morning, immediately after pulling out of a junction there was a slight bang from rear right wheel arch, which sounded similar to a tire blowout. My tyres are ready for a change and I presumed they had wore quicker than expected and give way, however after pulling over the tyres were fine so I tried to carry on my journey. The noise however carried on as a metal grinding noise and a slot bang every few seconds as though something is scraping. I managed to get the car home which wasn’t far and a very low speed.
My initial thought was a wheel bearing or something along them lines but the bearings haven’t been making the signature whine/howl noise prior to this and I have jacked the car up on that side and tested wheels for play, of which there doesn’t seem to be any.

All components seem strong and intact, as they should be and before it has to go into the garage I wondered if anybody had heard/seen of anything similar in the past.
i attempted to put on axle stands earlier today but I don’t have much faith in my trolley jack/stands and pussied out of it for the time being.

is it potentially something to do with the handbrake mechanism? I’ve had stones caught in the brake guard on my 987 and it doesn’t seem that innocent of a noise. I have inspected and no stones or debris in the brake disc area or guard.
Any help appreciated, video attached to listen to noise.

Thanks,
Chris

Video
 

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I don’t have much faith in my trolley jack/stands and pussied out of it for the time being. If you jack it up on the designated lift point, leave the jack in place and also place a cushioned stand under it in a well chosen spot, it's not going to fall. I made a custom set of lift aids with a plastic toilet bolt for the center opening (no scratching) and also bought some hockey pucks and carpeted them for extra care above the stands. You are not going under the vehicle to check this, so if you are mindful about the positioning of the jack and stands and are on level ground you can have confidence in the lift. Once it's off the ground on that side, manually rotate the tire, my guess is it's going to make that noise even without load. Then, if it were my ride I'd disassemble the Brembo and have a closer look than a through the wheel inspection provides. If it all looks clean no evidence of scoring then you need to proceed up the line to the shaft.
 

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The scrapping noise could be your emergency brake spring retainer that was pulled out of its backing plate hole. You will have to remove the wheel and the rear brake rotor to access this part. I had this experience happen to me as I backed my car out of the garage after setting a couple of days after a fresh wash. The soapy water caused my rear brake shoe to rust to the rear drum. On reverse out of the garage, the car did not move at first so I gave it more power, then bang. The two springs attaches the brake shoes to the backing plate. You will need 2 new springs and some heavy duty 90 degree long nose plyers to pull the spring back though their mounting holes. I tried to do this trick, the first spring was easy, but the second one could not do. I finally gave up and took the car to my local shop along with a couple of other jobs to do. Try not to use you emergency brake as it will only pull the whole brake assembly more out of alignment and more scraping noise, just take the brake shoes off that carrier and put them into a zip bag along with the springs. Hand them to your local repair shop. They will likely need to order two new springs. Then, just park your car in gear.

Think back, did you wash your car's rear wheels the day before and spray water all over the rear brake rotor? If so, after you fix your car, don't use that wash technique again it's a hassle and cost me $200. just for those 2 springs/labor.
 
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Also OP, while it’s never happened on my Cayman, I’ve had similar noises pop up more than once on other vehicles over the years and have discovered it to be a small pebble that’s been kicked up and has lodged up against the rotor by some other adjacent component. You’ll get scraping sound as the wheel turns along with the occasional pop as it contacts a drilled hole or slot in the rotor. Take a good look in there and maybe it’s something simple like this.
 
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You can easily check for a stone by backing up with a slight brake on. The stone will be dislodged by this action, as it happened to me. Not the same metal to metal effect of the rear brake pads on an angle rubbing against the inner drum brake. Just take it apart, takes a few tools (large allen wrench) to get the caliper off to release the rotor and hang the caliper on a coat hanger, then you will see what I am talking about. Then order the springs and a needle nose angled pliers to pull the new spring back through the backing support hole. Good luck.
 
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The trick to getting brake springs off and on is to use the right tool.. I've had one for 40 years, and it's saved me a lot of busted knuckles..

270989


They're called "Brake Pliers" (go figure..)

NAPA has them for $6.17. The round part on the one handle is for removing circular brake clips that hold brake shoes in place. There are (of course) YouTube videos explaining how to use them. Makes this kinda job a piece'a'cake.
 
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Discussion Starter #7
Thank you all so much for your replies. Unfortunately the weather in the UK meant I couldn’t look much further until last night and before checking this forum I had already thought it could be the handbrake.

I got that side jacked up and without the handbrake on, the wheel has some real resistance along with the grinding noise, which sounds like a spring loose in the hub.

It is definitely in and around that area which is good news to me and the car has gone in to a local garage for the repair as I have flew out to Cyprus.

Sorry in the delay of response, I’ll let you know the outcome for future cases but thanks again so much for the help and advise!

Chris
 

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So have got the car back today. The noise has gone and everything works but have lights on for PSM failure and ABS failure, so although I can get about now have to work out what is causing those failures.

Chris
 

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When braking there is a noise located behind the passenger side airbag (UK), like a very light ticking or electrical noise, it’s definitely related but unsure what it could be.
 

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This sounds like the repair shop accidently unplugged part of the ABS system to repair the emergency brake springs. What a hassle,
 
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I suppose it’s my own fault for taking it to the closest place instead of the right place. What will that have caused to happen or will they have simply put it back together incorrectly?
 

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I suppose it’s my own fault for taking it to the closest place instead of the right place. What will that have caused to happen or will they have simply put it back together incorrectly?
I don't know why putting it back together incorrectly will help. Perhaps if they put it back together correctly it might help.

And taking it to the closest place - rarely a good move unless you know they have a sterling reputation.

BTW - what did they do to stop the grinding-scrapping (scraping?) noise? That might give us a clue as to what they forgot to reconnect.
 
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Yeah I normally travel an hour to my most reputable specialist indie, but seen as though I was pretty short the handbrake had caused the problems, I didn’t want to take the car far so it didn’t need to be recovered.

They did as I asked and changed the handbrake shoes and springs which they said were pretty mangled.

They had trouble putting the handbrake assembly back together and used the opposite side as reference.

God knows what they have done but I’m unsure whether to risk letting them bother trying to fix it.

Just to add to my woes, I disconnected the battery to reset ECU and lights and accidentally shut the hood without it disconnected.

Going to attempt to find the emergency release cable tomorrow after attempting in the dark this evening and without removing the wheel.

This is one of the biggest IDIOT moments of owning Porsches but it happens!

Chris
 

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My takeaway is that if you find a really good shop, stay with them. Cheaper ones may be handy, but you usually get what you pay for.
 

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So I’m going to change the ABS sensor on Friday as that is what error code is thrown up. Something I have noticed above 60/70mph is a little bumpy feeling, again a bit like a flat tyre, but with a low kind of noise like a quiet helicopter. Very concerning but everything felt okay until I took it on the motorway. Just wondering if something could have been damaged when the handbrake failed.
 

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You might reset your ABS system. There are certain steps to follow to reset it. The handbrake is a manual pull wire, with a brake sensor under the handbrake lever itself under the wallet/key box.
 
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