Wilwood Forged Narrow Superlite 6R Big Brake Front Brake Kit (Hat) - Manual (Page 4)

Assembly Instructions (numbers in parenthesis refer to the parts list/diagram on the preceding pages): CAUTION: All mounting bolts
must fully engage insert nuts. Be sure to check that all bolts are either flush or protruding through flanged side of insert nut after shimming.
•The flat spindle/caliper mounting bracket (1) should be installed first with clean, dry threads on the mounting bolts. Install the bracket
on the back side of the spindle by sliding bolt (2) through the bracket (1) and into the upper hole of the spindle upright boss. Torque
bolt (2) to 140 ft-lb. Slide bolt (3) through lower spindle “ear”, through the bracket (1), washer (4), and secure with nut (5). Torque bolt
(3) to 77 ft-lb. The bracket must tighten squarely against the side of the spindle body. Inspect for interference from casting
irregularities, machining ridges, burrs, etc.
•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 bolts (9), and washers (8). Using an alternating
sequence, apply red Loctite® 271 to the threads and torque bolts to 155 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.
•Slide the rotor/hat assembly onto the spindle. Check to be sure the hat seats squarely
against the hub. Install a couple of lug nuts (finger tighten) to keep the rotor/hat assembly
in place while continuing with the installation.
•The radial mount caliper bracket assembly (11) should be installed first with clean, dry
threads on the mounting bolts. Slide bolt sleeve (10) into the mounting holes of bracket (11).
Install the bracket on the back side of the spindle/flat caliper mounting bracket (1) by sliding
bolt (12) through washer (13), and through sleeve (10.) Initially place three shim washers
(14) between the two brackets (1 and 11) (see Figure 1). The bracket must tighten
squarely against the side of the spindle/caliper bracket. Inspect for interference from
casting irregularities, machining ridges, burrs, etc. 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 47 ft-lbs.
•NOTE: This kit contains distinct right and left hand calipers that must be mounted in a specific direction, as described below. Lubricate
the caliper mounting studs (19) with lightweight oil. Initially place .035” thick shim (21) and one spacer (20) on each stud as shown in
Figure 1. Mount the caliper (16) onto the radial mount bracket (11) using lock nuts (17) and washers (18), Figure 1. Ensure that the
caliper is mounted so that the largest pistons are at the rotor exit end of the caliper, in relation to the direction of rotor rotation.
Temporarily tighten the lock nuts and view the rotor through the top opening of the caliper. The rotor should be centered in the caliper.
If not, adjust by adding or subtracting shims (14 and/or 15) between the spindle/caliper bracket (1) and the radial mount bracket (11).
Always use the same amount of shims on each of the two mounting bolts.
•Remove the caliper center bridge pad retainer bolt, nut, and tube from the caliper. Slide the brake pads (22) into place. They should
install easily without interference. Check that the outside radius of the brake pad is flush with the outside diameter of the rotor face.
Add or subtract shims (21) between the caliper and mount bracket to gain the proper alignment. Reinstall the center bridge pad
retainer tube, bolt, and locknut. The locknut should be snug without play in the bolt or tube. Be cautious not to over tighten.
•Remove the lug nuts that were holding the hat 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, hat, and rotor from the spindle and hub. Secure the
spindle/caliper mounting bracket (1) to the spindle with bolts (2 and 3) using red Loctite ® 271 on the bolt threads. Torque bolt (2) to
140 ft-lb and bolt (3) to 77 ft-lb. Remove bolts (12) from the radial mount caliper bracket (11) and coat threads with red Loctite ® 271
and reinstall. NOTE: Only removing one bolt at a time, then coating the threads and reinstalling will help keep all the shims in place.
Torque bolts (12) to 47 ft-lb. Reinstall the hat and rotor assembly and again use lug nuts to hold it in place. Reinstall the caliper (16),
torque the caliper nuts (17) to 28 ft-lb.
•NOTE: OEM rubber brake hoses generally cannot be adapted to Wilwood calipers. The caliper inlet fitting is a 1/8-27 NPT. 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. Wilwood offers a hose kit, P/N 220-10631,
which includes hoses, fittings, etc., all in one package for this application.
Assembly Instructions
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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