Wilwood W4A Big Brake Front Brake Kit (Race) - Manual (Page 4)

Assembly Instructions
Assembly Instructions (numbers in parenthesis refer to the part list/diagram on the preceding page):
•The caliper mount bracket assembly (1) should be installed first with clean, dry threads on the mounting bolts. Install the bracket using
the original caliper mount bolts. The bracket must tighten squarely against the outboard side of the caliper mount bosses on the
spindle body. Inspect for interference from casting irregularities, machining ridges, burrs, etc. Use one thin shim (2) between the
bracket and spindle during initial trial fitting. Later, after the caliper, pad, and rotor alignment has been checked, and any necessary
shims have been put in place, the mount bolts should be coated with red Loctite
® 271 and torqued to 65 ft-lbs.
• Assemble the rotor (3) to the hat (4) with the bolts (6), washers (5) and t-nuts (7) as
shown in the configuration pictured in Figure 1. Follow all additional instructions included with
the bolt kit. Using an alternating sequence, apply red Loctite® 271 to the threads and torque
bolts to 120 in-lb. For an added measure of security, the bolts may be safety wired 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 three lug nuts to hold the rotor and hat firmly against the hub during the
next phases of the installation and clearance checking procedures.
• Install one shim (12) and spacer (13) over each stud (11) on the radial mount bracket (1). Slide
the caliper (8) in place over the studs and rotor and install the washer (10) and lock nut (9) to
hold the caliper in place. The caliper bleed screws should be pointing up. Snug the lock nuts
(9) and check that the rotor (3) is centered in the caliper (8). Add or subtract .029" shims (2)
as necessary between the mount bracket and the spindle to center the caliper.
• Remove the two caliper pad retaining pins from the caliper (8) by popping out the pin retaining clips and sliding out the pins. Slide the
brake pads (14) into place. They should install easily without interference. Check that the outside radius of the brake pad is aligned
with the outside diameter radius of the rotor face. Add or subtract shims (12) between the caliper and mount bracket to gain the proper
alignment. Reinstall the pad retaining pins and secure using the pin retaining clips
• Remove the lug nuts that were holding the hat in place. Install the wheel and torque the lug nuts to specification. Check to see that
the wheel rotates freely without interference.
• Once all clearances have been checked, remove the wheel,
caliper, hat, and rotor from the spindle and hub. Secure the caliper
mounting bracket (1) to the spindle using red Loctite
® 271.
Torque the bolts to 65 ft-lbs. Reinstall the hat and rotor assembly
and again use several lug nuts to hold it in place. Lubricate caliper
mounting studs and nuts with lightweight oil, reinstall the caliper,
torque the caliper nuts (9) to 47 ft-lbs.
Stock Brake Line Disassembly Instructions
•Unbolt banjo bolt from back of caliper.
•Unbolt rubber hose from hard line at frame.
•Pull the clip that holds the rubber hose to the bracket at the frame.
On some models, it will be necessary to re-use these clips to retain
the new hoses.
Installing the New Flexlines
•Purchase flexline hose kit part number 220-8176 for all 1997-2004 (C-5), or part number 220-9100 for all 2005-present (C-6). Be sure
to follow any additional instructions provided with the line kit. These line kits are not included with the brake it.
FLEXLINE
BRACKET
CLIP
90° ELBOW
FRAME
HARDLINE
WILWOOD
W6A CALIPER
Figure 4. Brake Line Diagram
BEGIN BY SLIDING THE 0.032"
DIAMETER WIRE THROUGH TWO OF
THE HOLES (LEFT) THAT ARE 180°
APART. TWIST THE WIRE AS
SHOWN (BELOW) USING SAFETY
WIRE PLIERS. NOW SLIDE ONE
WIRE THROUGH TWO OF THE
HOLES (180° APART) AND WRAP THE
OTHER WIRE AROUND THE BOLT.
TWIST THE WIRES TOGETHER TO
FORM A PIGTAIL. SEE DS-386 FOR
COMPLETE DETAILS.
Figure 3. Safety Wire Diagram
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