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Photographic tip – Wilwood D154 Rear Caliper Kits User Manual

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Installation of this kit should ONLY be performed by individuals experienced in the installation and proper operation of disc brake

systems. Before assembling the Wilwood kit, double check the following to ensure a trouble-free installation.

• Make sure this is the correct kit to fit vehicle application. This kit is intended for use as a rear caliper for vehicle rear ends modified to

use 1.04” rotor width OEM D154 style calipers by welding or bolting on brackets to attach to the rear end.

• Inspect the contents of this kit against the parts list to ensure that all components and hardware are included.

WARNING: Caliper does not have a provision for parking brake. It is recommended that an additional parking brake mechanism be

installed in the vehicle for street use.

Disassembly
• Disassemble the rear brakes, if assembled: Raise the rear wheels off the ground and support the rear suspension according to the

vehicle manufacturer’s instructions.

• Remove the rear wheels, existing D154 calipers, and brake hoses (if installing replacements). NOTE: It is recommended that the brake

hoses be replaced for all applications with braided steel hoses, refer to the assembly instructions below.

• Clean and de-grease the caliper mounting brackets.

• To ensure proper action of the caliper, brackets must be square and parallel to the rotor face. Bent or poorly installed brackets can

cause caliper pistons to stick and accelerated or uneven pad wear.

NOTE: It is recommended that the rotors be replaced or lathe turned by a qualified machine shop, prior to installing the Wilwood kit.

Assembly Instructions (numbers in parenthesis refer to the
parts list/photo on the preceding page): CAUTION: All mounting
bolts must fully engage threaded holes.
• Install the disc brake pads (1) into the caliper (2) with the friction

material facing the rotor, as shown in Photo 2.

• Install sleeves (3) onto slide pin bolts (4). Apply white lithium

grease (available from your local auto parts store) to the slide
pins/sleeves, as shown in Photo 3. Do not apply to threads.
Mount the caliper onto the OEM mounting bracket using slide pin
bolts, as shown in Photo 4. Torque to 35 ft-lbs.

• Check wheel clearance: Gently slide the caliper inboard, so as to remove any excess gap between

the outboard brake pad, the rotor face and the caliper. This will approximate the location of the
caliper in service. Temporarily install the wheel and torque lug nuts to manufacturer’s specification.
Ensure that the wheel rotates freely without any interference.

•Once the wheel clearance has been confirmed, remove wheel and connect brake hose as outlined below.

•NOTE: The caliper in this brake kit utilizes a 10mm x 1.50 thread inlet. OEM rubber brake hoses

with 10mm fittings can be adapted to Wilwood D154 calipers. The preferred method is to use steel
banjo adapter fittings at the caliper, and enough steel braided line to allow for full suspension travel
and turning radius, lock to lock. Carefully route hoses to prevent contact with moving
suspension, brake or wheel components. NOTE:
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

General Information, Disassembly, and Assembly Instructions

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Photo 2

Photo 3

Photo 4

Photographic Tip

Important and highly recommended: Take photos of brake system before disassembly and during the disassembly process. In the
event, trouble-shooting photos can be life savers. Many vehicles have undocumented variations, photos will make it much simpler for
Wilwood to assist you if you have a problem.