Wilwood D154 Front Caliper Kits - Manual (Page 3)

• Installation of this kit should ONLY be performed by individuals experienced in the installation and proper operation of disc brake
systems. Before assembling the Wilwood kit, double check the following to ensure a trouble-free installation.
• Make sure this is the correct kit to fit the exact make and model year of the vehicle’s spindle. This kit is designed for direct bolt-on
installation to 1978 through 2002 model year General Motors vehicles, using D154 style calipers with a 1.04” rotor width only.
• Inspect the contents of this kit against the parts list to ensure that all components and hardware are included.
Disassembly
• Disassemble the original equipment front brakes: Raise the front wheels off the ground and support the front suspension according to
the vehicle manufacturer’s instructions.
• Remove the front wheels, factory calipers, and brake hoses (if installing replacements). NOTE: It is recommended that the brake hoses
be replaced for all applications with braided steel hoses, refer to the assembly instructions below.
• Clean and de-grease the caliper mounting area of the spindle.
• NOTE: It is recommended that the rotors be replaced or lathe turned by a qualified machine shop, prior to installing the Wilwood kit.
Assembly Instructions (numbers in parenthesis refer to the parts list/photo on the preceding page): CAUTION: All mounting bolts must
fully engage threaded holes.
• Install the disc brake pads (1) into the caliper (2) with the friction
material facing the rotor, as shown in Photo 2.
• Install sleeves (3) onto slide pin bolts (4). Apply white lithium
grease (available from your local auto parts store) to the slide
pins/sleeves, as shown in Photo 3. Do not apply to threads.
Mount the caliper onto the OEM mounting bracket using slide pin
bolts, as shown in Photo 4. Torque to 35 ft-lbs.
• Check wheel clearance: Gently slide the caliper inboard, so as
to remove any excess gap between the outboard brake pad, the
rotor face and the caliper. This will approximate the location of
the caliper in service. Temporarily install the wheel and torque
lug nuts to manufacturer’s specification. Ensure that the wheel
rotates freely without any interference.
•Once the wheel clearance has been confirmed, remove wheel and connect brake hose as outlined
below.
•NOTE: The caliper in this brake kit utilizes a 10mm x 1.50 thread inlet. OEM rubber brake hoses
with 10mm fittings can be adapted to Wilwood D154 calipers. The preferred method is to use steel
banjo adapter fittings at the caliper, and enough steel braided line to allow for full suspension travel
and turning radius, lock to lock. Carefully route hoses to prevent contact with moving
suspension, brake or wheel components. NOTE: 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 universal brake flex
line hose kits, for 3/8-24 IF chassis fittings order P/N 220-12104 for the 14 inch length,
General Information, Disassembly, and Assembly Instructions
Page 3
Photo 2 Photo 3
Photo 4
Photographic Tip
Important and highly recommended: Take photos of brake system before disassembly and during the disassembly process. In the
event, trouble-shooting photos can be life savers. Many vehicles have undocumented variations, photos will make it much simpler for
Wilwood to assist you if you have a problem.