• To ensure maximum performance from your parking brake system, the cables must be routed as straight as possible. Bends in the cable can significantly reduce efficiency and thus reduce pull force at the brake. Tight bends must be avoided with a minimum recommended bend radius of 6" to 8".
• Cables should be properly restrained to prevent "straightening" of bends when tension is applied. Restrain movement of cable by affixing the cable sheath to body or chassis by fitting cable clamps at various points over the length of cable or by using original equipment cable attachments points. The clamping method chosen will require that cable sheath be held tightly without movement, crushing or causing interference to the internal cable.
• Cables must be initially pre-stretched by multiple applications of the brake handle, then re-adjusted to correct tension.
Assembly Instructions(numbers in parenthesis refer to the part list/diagram on the preceding page):
•The caliper mounting bracket (1) should be installed first with clean, dry threads on the mounting bolts. Install the bracket (1) on the outboard side of the stock bracket by sliding bolt (2) from the inboard side of the hub assembly through washer (3) and the sleeve (4) which is inserted inside the existing OEM caliper mounting holes. Place two shim washers (16) between the hub and the caliper mounting bracket (1). The mounting bracket (1) must tighten squarely against the outboard side of the stock bracket face. Inspect for interference from casting irregularities, machining ridges, burrs, etc. Use two shims (16) between the mounting bracket (1) and stock
bracket during initial trial fitting.
•With the larger I.D. side of the rotor (6) facing away from the hat (7), bolt rotor (6) to hat (7) through the backside of the rotor using washers (8), and bolts (9). Be sure all bolts thread in smoothly and are snug. Then, torque all bolts in an alternating sequence to 103 in-lbs. The rotor mounting bolts (9) must be lockwired using standard 0.032 inch diameter stainless steel safety wire as shown in Figure 3. Please refer to Wilwood’s data sheet DS-386 (available at www.wilwood.com/Pdf/DataSheets/ds386.pdf) for complete safety wire installation instructions.
•Install the hat and rotor assembly onto the hub. Check to be sure the hat seats squarely against the hub. The hub must be free from any rust, debris, casting burrs, machining irregularities, etc. Use several lug nuts to hold the rotor and hat firmly against the hub during the next phases of the installation and clearance checking procedures.
•Slide the brake pads (15) up into the caliper (10) from the bottom until the “v” spring clip snaps into place against the anvil. They should install easily without interference.
•Lubricate caliper mounting studs and nuts with lightweight oil. Install two shims (14) over each stud (13) on the radial mount bracket (2). Slide the caliper (10) in place over the studs and rotor and install the washer (12) and lock nut (11) to hold the caliper in place. The caliper bleed screw should be pointing toward the rear of the vehicle. Snug the lock nuts (11) and check that the caliper (10) is centered over the rotor (6). Add or subtract .016" shims (5) and/or .030 shims (16) as necessary between the caliper mounting bracket (1) and the stock bracket to center the caliper (10) on the rotor (6).
•Check that the outside radius of the brake pad (15) is aligned with the outside diameter radius of the rotor face. Add or subtract shims (14) between the caliper (10) and caliper mounting bracket (1) to gain the proper alignment.
•Remove the lug nuts that were holding the hat/rotor in place. Install the wheel and torque the lug nuts to manufacturer’s specification. Check to see that the wheel rotates freely without interference.
•Once all clearances have been checked, remove the wheel, caliper and rotor from the axle flange. Secure the caliper mounting bracket (1) to the spindle face while applying red Loctite ® 271 on the bolt threads (2). Torque the bolts (2) to 35 ft-lbs.. Reinstall the rotor and again use several lug nuts to hold it in place. Reinstall the caliper, torque the caliper nuts (11) to 30 ft-lbs.
•NOTE: OEM rubber brake hoses generally cannot be adapted to Wilwood calipers. The caliper inlet fitting is a M10 x 1.0 banjo. The preferred method is to use steel adapter fittings at the caliper, either straight, 45 or 90 degree and enough steel braided line to allow for full suspension travel and turning radius, lock to lock. Carefully route lines to prevent contact with moving suspension, brake or wheel components. Wilwood hose kits are designed for use in many different vehicle applications and it is the installer's responsibility to properly route and ensure adequate clearance and retention for brake hose components.
•Specified brake hose kits may not work with all Years, Makes and Models of vehicle that this brake kit is applicable to, due to possible OEM manufacturing changes during a production vehicle's life. It is the installer's responsibility to ensure that all fittings and hoses are the correct size and length, to ensure proper sealing and that they will not be subject to crimping, strain and abrasion from vibration or interference with suspension components, brake rotor or wheel.
•In absence of specific instructions for brake line routing, the installer must use his best professional judgment on correct routing and retention of lines to ensure safe operation. Test vehicle brake system per the 'minimum test' procedure stated within this document before driving. After road testing, inspect for leaks and interference. Initially after install and testing, perform frequent checks of the vehicle brake system and lines before driving, to confirm that there is no undue wear or interference not apparent from the initial test. Afterwards, perform periodic inspections for function, leaks and wear in a interval relative to the usage of vehicle.
•Repeat this entire procedure for the other wheel.
•Bleed the brake system. Reference the general information and recommendations on page 5 for proper bleeding instructions.
•NOTE: The parking brake lock is cable actuated. Connections are made with common cable ends that use 1/2” cable housing on the stop bracket, and a 1/8” to 9/64” cable with a crimped or welded ball end. The caliper will accept the original equipment cable on some vehicles. For other vehicles, new cable ends must be ordered to adapt the caliper to the vehicle’s original cable system. For custom
installations, aftermarket hand brake kit suppliers can easily configure the cable with the correct attachment end.
•Install new parking brake cable (not included with kit). Wilwood offers a generic style parking brake cable kit, P/N 330-9371 and adapters, 2 required (please call for specific application) for this kit which can be ordered separately from your local Wilwood dealer or by calling Wilwood customer service at (805) 388-1188. NOTE: Original equipment cable will not adapt to Wilwood calipers.
•Remove the lug nuts that were used to hold the hat/rotor assembly in place during caliper installation. Install the wheel and torque the lug nuts to OEM specifications.
•Depress and hold brake pedal using moderate leg pressure. While maintaining leg pressure on the pedal, completely engage and disengage parking brake lever until lever tension becomes consistent. This will set the adjusting mechanism for the parking brake while tightening the lever feel.
•Bed in your brake pads per the procedure on the last page.
• After brake pads have been bedded, test the parking brake function on a slight slope. Depress brake pedal, then apply parking brake. Release brake pedal.