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

Disassembly Instructions (Continued) and Assembly Instructions
•Remove the wheel. Remove the two bolts from the backside of the spindle that hold the stock caliper mounting bracket and lift off the
bracket and stock caliper as one unit. If space is a problem, you may have to unbolt the stock caliper from the caliper bracket before
removal. Remove dust face plate.
•Clean and de-grease the spindles. Remove all nicks or burrs on the spindle snout and threads.
Assembly Instructions (numbers in parenthesis refer to the part 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 insert nut after shimming.
•The caliper mount bracket assembly (1) should be installed first with clean, dry threads on the mounting bolts. Install the bracket on the
inboard side of the spindle by sliding bolt (2) through flat washer (3), and spindle ear from the outboard side of the spindle. Place two
shim washers (4) between the bracket (1) and the spindle (see figure 1). The bracket must tighten squarely against the inboard side
of the caliper mount bosses on the spindle body. 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 65 ft-lbs.
•With the larger I.D. side of the rotor (6) facing away from the hat (7), attach the rotor (6)
to the hat (7) using washers (8) and bolts (9) as shown in Figure 1. Using an alternating
sequence, apply red Loctite® 271 to the threads and torque bolts to 25 ft-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 axle 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.
•Lubricate caliper mounting studs (13) and nuts (11) with lightweight oil. Install two shims (14)
over each stud (13) on the radial mount bracket. Slide the caliper (10) in place over the studs
and rotor and install the washer (12) and lock nut (11) to hold the caliper in place. The caliper
bleed screws should be pointing up. Snug the lock nuts (11) and check that the rotor (6) is
centered in the caliper (10). Add or subtract shims (4 and/or 5) as necessary between the
mount bracket and the spindle to center the caliper.
•Remove the caliper center bridge pad retainer bolt, nut, and tube from the caliper. Slide the brake pads (15) 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 (14) between the caliper and mount bracket to gain the proper alignment. Reinstall the center bridge pad retainer
tube, bolt, and lock nut. 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 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. Reinstall the caliper, torque the caliper nuts (11) to 30 ft-lbs.
•Install braided flexline kit part number 220-6746. The 10mm x 1 to -3 (P/N 220-6890) male fitting installs to the stock bulkhead. Then
install the straight 1/8-27 to -3 NPT (P/N 220-6956) fitting into the caliper (10). Finally, install the flex line (P/N 220-6746) to
the two previously installed fitting. 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.
•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.
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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