Wilwood Superlite 6R Big Brake Front Brake Kit (Race) - Manual (Page 4)

Assembly Instructions (numbers in parenthesis refer to the part list/diagram on the preceding pages):
•The caliper mount bracket assembly (1) should be installed first with clean, dry threads on the mounting bolts. Install the bracket using
the original caliper mount bolts. The bolts will now pass through the spindle from the opposite direction that they were removed (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. Use one thin shim (2) between the bracket and spindle during
initial trial fitting. 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.
•Assemble the rotor (3) to the hat (4) with the bolts (6) and washers (5) provided in the configuration
pictured in Figure 1. Be sure all bolts thread in smoothly and are snug. 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.
•Install the hat and rotor assembly onto the 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 several lug nuts to hold the rotor and hat firmly against the hub during
the next phases of the installation and clearance checking procedures.
• Install one shim (11) over each stud (10) on the radial mount bracket. Slide the caliper (7) in
place over the studs and rotors and install the washer (9) and lock nut (8) to hold the caliper
in place. The caliper bleed screws should be pointing up. Snug the lock nuts (8) and check
that the rotor (3) is centered in the caliper (7). Add or subtract .033" shims (2) 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 (12) 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 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 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. Lubricate caliper mounting studs and nuts with lightweight oil, reinstall the caliper, torque the
caliper nuts (8) to 30 ft-lbs.
•Install braided flex line 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 (7). Finally, install the flex line (P/N 220-6411) to the two
previously installed fitting. NOTE: Carefully route lines to prevent contact with moving suspension, brake, or wheel
components. Periodically check hose and components for any wear. Wilwood brake and 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.
•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 below for proper bleeding instructions.
•Repeat the procedure for the other wheel.
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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