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

Assembly Instructions (numbers in parenthesis refer to the parts list/diagram on the preceding page): 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 each insert nut after shimming.
•The caliper mounting bracket assembly (1) should be
installed first with clean, dry threads on the mounting
bolts. Install the bracket from the outboard side of the
spindle by sliding the bolt (2) through washer (3) and
bracket (1). Place shim washer (4) between the bracket
(1) and the spindle (see Figure 1). The bracket must
tighten squarely against the side of the spindle body.
Inspect for interference from casting irregularities,
machining ridges, burrs, etc. Use one thin shim (4)
between the bracket (1) and spindle during initial trial
fitting.
•With the larger I.D. side of the rotor (5) facing away from
the hat (6), attach rotor (5) to hat (6) using bolts (8) as
shown in Figure 1. Finger tighten. Using an alternating
sequence, remove bolts (8) one at a time, apply red
Loctite
® 271 to the threads and torque to 25 ft-lb.
•NOTE: The bottom section of the dust shield needs to
be cut away to allow clearance for the new hat and rotor.
•Slide the rotor/hat assembly onto the spindle. NOTE:
The rotor/hat must fit flush against the hub face or
excessive rotor runout may result. Install three lug nuts
(finger tight) to keep the rotor/hat assembly in place
while continuing with the installation.
•NOTE: Please reference the caution statement at the beginning of the assembly instructions. Install two spacers (10) and one shim
washer (11) over each pre-installed stud (12) on the radial mount bracket (1). Slide the caliper (9) in place over the studs and rotors
and install the washer (13) and lock nut (14) to hold the caliper in place. The caliper bleed screws should be pointing up. Snug the lock
nuts (14) and check that the rotor (5) is centered in the caliper (9). Add or subtract .029" shims (4) as necessary between the caliper
mounting bracket (1) and the spindle to center the caliper (9).
•Remove the two caliper center bridge pad retainer bolts, nuts, and tubes from the caliper. Slide the brake pads (7) 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 (11) between the caliper and mount bracket to gain the proper alignment. Reinstall the center
bridge pad retainer tubes, bolts, and locknuts. 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 nut 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 with bolts (2) using red Loctite ® 271. Torque the bolts to 70 ft-lb. Reinstall the hat and rotor
assembly and again use lug nuts to hold it in place. Lubricate caliper mounting studs and nuts with lightweight oil, reinstall the caliper,
torque the caliper nuts (14) to 47 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 220-8998
(1999-2006), and P/N 220-10980 (2007-2011) which includes hoses, fittings, etc., all in one package for this application.
Assembly Instructions
SPINDLE
SIDE VIEW
SPINDLE
TOP VIEW
STOCK MOUNTING EAR
SIDE VIEW
MACHINED EAR
SIDE VIEW
(REMOVE ONLY ENOUGH
MATERIAL FOR BRACKET
TO FIT FLUSH AND SQUARE)
THESE AREAS
(SHADED)
MAY NEED TO BE
MACHINED
SMOOTH
THESE
AREAS
CASTING
PARTING LINE
LATE MODEL SPINDLES MAY REQUIRE MACHINING (BLACK AREA) WITH A GRINDING WHEEL TO ALLOW THE WILWOOD
CALIPER BRACKET TO FIT. SMOOTH THE AREA AT THE CASTING PARTING LINE AT THE ORIGINAL CALIPER MOUNT
TAB OR EAR, REMOVING ONLY ENOUGHT MATERIAL FOR THE WILWOOD CALIPER BRACKET (1) TO FIT FLUSH AND
SQUARE TO THE SPINDLE AND ALLOW MOUNT ATTACHMENT BOLTS (2) TO ALIGN AND THREAD WITHOUT BINDING.
Figure 3. Machining Diagram
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