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

Disassembly (Continued) and Assembly Instructions
•Remove only the upper OEM caliper mounting ear making sure all the
material required to mount the front strut is still intact. Remove all sharp
corners and burrs with a file or grinder.
•Drill out the three dust plate mounting holes in the spindle face with a 5/16
inch (.312) diameter drill. Tap the three holes with a 3/8-16 UNC tap (these
three holes will be used to mount the caliper mounting bracket). Verify that
there are no raised burrs on the spindle face that may interfere with the
assembly of the disc brake kit components.
Assembly Instructions (numbers in parenthesis refer to the part list/diagram
on the preceding page):
•Apply red Loctite® 271 to bolt threads (3) before assembly of the caliper
mounting bracket (1). Mount bracket (1) to face of spindle using washers (2)
and bolts (3). Torque bolts to 35 ft-lb. NOTE: Be sure the heads of the
bracket clinch nuts are facing outboard.
•Install wheel studs (4) into the hub (5). Torque to 77 ft-lb.
•Pack the large inner bearing cone (6) with high temperature disc brake
bearing grease (available from your local auto parts store) and install into the
backside of the hub (5). Install the grease seal (7) by pressing into the
backside of the hub (5).
•Pack the small outer bearing cone (8) with high temperature disc brake
bearing grease and install into front of hub (5). Slide the hub with outer
bearing cone (8) onto the spindle. Secure using stock washer, adjusting nut
and nut locking device. Adjust bearings per Original Equipment
Manufacturer (OEM) specifications.
•Install the dust cap (10) onto the hub (5). Friction created by the o-ring (9) on the dust cap
(10) keeps it from unscrewing. The O.D. of the existing spindle washer may be larger
than the I.D. of the dust cap (10) not allowing it to seat against the hub face. Some
grinding on the washer O.D. may be necessary to clear the I.D. of the dust cap (10).
•Orient the rotor (11) and hat (12), as shown in Figure 1. Attach rotor to the hat using
washers (13) and bolts (14). 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 4. Please refer to Wilwood’s data sheet DS-386 (available at
www.wilwood.com/Pdf/DataSheets/ds386.pdf ) for complete safety wire installation
instructions.
•With the bleed screws pointing up, mount the caliper (16) onto the caliper bracket (1)
using bolts (19), and caliper spacer (15) positioned between caliper and bracket, as
shown in Figure 1. Finger tighten. View the rotor (11) through the top opening of the
caliper. The rotor should be aligned in the center of the caliper. If not, adjust the caliper
by using 0.030 inch thick shims (17) placed between the caliper spacer and the caliper,
as shown in Figure 1. Finger tighten and recheck alignment. Apply red Loctite® 271 to
bolt threads and torque to 55 ft-lb.
•Remove the bridge bolt from the caliper (16) and install the disc brake pads (20). Reinstall the caliper bridge bolt.
•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 220-6471,
which includes hoses, fittings, etc., all in one package for this application.
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 4. Safety Wire Diagram
CALIPER OUTLINE
SHOWN FOR REF
INSIDE WHEEL PROFILE
(MINIMUM REQUIRED
FOR CLEARANCE)
.25 HAT THICKNESS
REFERENCE
FACE OF WILWOOD HUB
FACE OF WILWOOD HAT
STOCK WHEEL MOUNTING
SURFACE OFFSET
.125 (3,2) OFFSET CHANGE
CENTER
LINE OF
WHEEL
1.56
(39,6)
.69 (17,5)
7.32
(185,9)
6.81
(173,0)
4.35
(110,5)
WILWOOD
WHEEL STUDS
WILWOOD
ROTOR
CALIPER
Figure 3. Wheel Clearance Diagram
Page 4