Wilwood TC6R Big Brake Truck Rear Brake Kit - Manual (Page 4)

Assembly Instructions
• The caliper mount bracket assembly (1) should be installed first with clean, dry threads on the mounting bolts (2). Install the bracket by
sliding bolt (2) through shim washer (3) from the rear side of the hub through the OEM caliper mounting bracket ears, then through an
additional shim washer (4) and into the bracket (1). The bracket must tighten squarely against the outboard side of the caliper mount
bosses on the upright. Inspect for interference from casting irregularities, machining ridges, burrs, etc. Use one shim (4) between the
bracket and upright during initial trial fitting. Later, after the caliper, pad, and rotor alignment have been checked, and any necessary
shims have been put in place, the mounting bolt threads (2) should be coated with red Loctite
® 271 and torqued to 95 ft-lbs.
• Attach the rotor (5) to the hat (6) using bolts (8) and washers (7) as shown in Figure 1. Using
an alternating sequence, remove bolts one at a time, apply red Loctite ® 271 to the threads, and
torque to 198 in-lbs. Safety wire bolts 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.
• Align the hole pattern on the hat and rotor assembly (5 and 6) with the stud pattern on the axle
flange. Slide the hat/rotor assembly (5 and 6) over the wheel studs and against the axle flange
face. Check to be sure the hat seats squarely against the axle flange face. The axle flange
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 axle flange during the next phases of the
installation and clearance checking procedures.
• Lubricate caliper mounting studs and nuts with lightweight oil. Install one shim (13) over each
stud (12) on the radial mount bracket (1). Slide the caliper (9) in place over the studs and rotor
and install the washers (11) [up to 4 may be required on each side to keep the lock nut from
bottoming out on the stud], and lock nut (10) to hold the caliper in place. The caliper bleed
screws should be pointing up. Snug the lock nuts (10) and check that the rotor (5) is centered
in the caliper (9). Add or subtract .029" shims (4) as necessary between the caliper mount
bracket and the caliper mount bosses on the upright assembly to center the caliper.
•Remove the two caliper center bridge pad retainer bolts, nuts, and tubes from the caliper. Slide the brake pads (3) 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 (13) between the caliper and mount bracket to gain the proper alignment. Reinstall the two center
bridge pad retainer tubes, bolts, and lock nuts. 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 rotor 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 and rotor from the axle flange. Secure the caliper mounting bracket
(1) to the axle flange body with bolts (2) while coating the threads with red Loctite ® 271. Torque the bolts to 75 ft-lbs. Reinstall the
rotor and again use several lug nuts to hold it in place. Reinstall the caliper, torque the caliper nuts (10) to 47 ft-lbs.
•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 220-9811
(1999-2006) and P/N 220-11196 (2007-2011), which includes hoses, fittings, etc., all in one package for this application.
•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.
•Bleed the brake system. Reference the general information and recommendations on page 5 for proper bleeding instructions..
•Install the wheel and torque the lug nuts to specification. If necessary, adjust the parking brake shoes to factory specifications.
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
Page 4