INSTALLATION INSTRUCTIONS FOR FRONT BRAKE KITS 

 

(1)  JACK UP CAR.  SUPPORT ON JACK STANDS.  REMOVE WHEELS.

 

(2)  REMOVE THE STOCK CALIPER.  REMOVE THE FRONT HUB AND ROTOR ASSEMBLY.  REMOVE THE BACKING PLATE.

 

(3)  REMOVE THE STOCK ROTOR FROM THE HUB.  CLEAN THE ROTOR MOUNTING SURFACE.  ALSO CLEAN THE CALIPER MOUNTING SURFACE ON THE STRUTS.

 

(4)  BOLT THE ROTOR TO THE BRAKE HAT.  THE ROTOR AND HAT ASSEMBLY CAN NOW BE INSTALLED ON THE CLEANED HUB ASSEMBLY.  IT WILL BE NECESSARY TO HEAT THE HAT SLIGHTLY IN ORDER TO ALLOW IT TO DROP ONTO THE HUB.  (THIS INTERFERENCE FIT IS DONE TO ACCOUNT FOR THE DIFFERENCE IN EXPANSION RATES OF THE ALUMINUM HAT AND IRON HUB.)  BOLT THE HAT TO THE HUB.

 

(5)  THE HUB CAN NOW BE REINSTALLED ON THE STRUT.

 

(6)  AT THIS POINT IT IS A GOOD IDEA TO CHECK THE CLEARANCE BETWEEN THE LOWER CONTROL ARM AND THE ROTOR.  IT IS SOMETIMES NECESSARY TO GRIND THE CONTROL ARM FOR CLEARANCE.  BE SURE TO CHECK THIS CLEARANCE WITH THE WHEELS TURNED AS WELL AS STRAIGHT.  ALSO, IT IS WISE TO MOVE THE SUSPENSION THROUGH IT'S RANGE OF TRAVEL TO CHECK CLEARANCE.  THIS CHECK IS PARTICULARLY CRITICAL ON CARS THAT HAVE KNUCKLE RISERS ("BUMP STEER SPACERS").

 

(7)  INSTALL THE BRACKET TO THE BRAKE CALIPER WITH THE SUPPLIED BOLTS, WASHERS, AND LOCK NUTS.  THE CALIPER WILL TILT UP SLIGHTLY AND THE BLEEDER SCREWS SHOULD BE ON TOP.  BOLT THE CALIPER/BRACKET ASSEMBLY TO THE STRUT USING THE SUPPLIED 12mm BOLTS, FLAT WASHERS, AND LOCK WASHERS.  AGAIN STEER THE CAR RIGHT AND LEFT TO BE SURE THERE ARE NO INTERFERENCE PROBLEMS.

 

(8)  AT THIS POINT, IT IS A GOOD IDEA TO PLACE THE WHEEL ONTO THE HUB TO CHECK FOR INTERFERENCE  WITH THE CALIPER.  ONCE IT IS DETERMINED THAT THERE IS NO INTERFERENCE WITH THE WHEEL, REMOVE THE WHEEL AND  INSTALL THE BRAKE PADS.

 

(9)  NOW INSTALL THE SUPPLIED FITTING INTO THE CALIPER USING TEFLON TAPE, AND RUN A BRAKE LINE TO THE CALIPER.

 

(10)  BLEED THE BRAKES AND CHECK FOR LEAKS.

 

(11)  REINSTALL THE WHEEL AND LOWER THE CAR.

 

(12)  ANYTIME YOU INSTALL BRAKES, IT IS A GOOD IDEA TO DRIVE THE CAR CONSERVATIVELY FOR A WHILE.  LISTEN FOR ANY SUSPECT NOISES AND MAKE SURE EVERYTHING FEELS ALRIGHT BEFORE YOU REALLY RELY ON THEM.  ONCE YOU ARE CERTAIN THERE ARE NO INTERFERENCE PROBLEMS, LEAKS, ETC., YOU CAN USE THE BRAKES HARDER.  AGAIN BE CAUTIOUS, YOU DON'T WANT REAR WHEEL LOCKUP.  IF YOU SUSPECT THIS IS OCCURRING, INSTALL A PROPORTIONING VALVE IN THE REAR LINE SO THAT YOU CAN REDUCE THE REAR BRAKE PRESSURE UNTIL THE LOCKUP GOES AWAY.  ALSO, IT IS  A GOOD IDEA TO CHECK ALL OF THE BOLTS TO BE SURE THEY ARE STILL TIGHT AFTER THE CAR HAS BEEN DRIVEN FOR A WHILE.