Wilwood Forged Dynalite Front Drag Brake Kit (Hat) - Manual (Page 5)

Assembly Instructions
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.
•Insert one sleeve (2) each into the holes on the top and bottom of the spindle “ears” where the
OEM caliper bracket was removed. Apply red Loctite® 271 to the caliper mounting bracket bolt
threads (4) before installation of the caliper mounting bracket (1). Install the caliper mounting
bracket (1) with the threaded inserts and the beveled bolt holes facing the outside of the
vehicle. Slide bolt (4) through washer (3) into the previously installed sleeve (2) from the
backside of the spindle. Finger tighten. Repeat for the lower mounting hole. Torque bolts to
40 ft-lb. NOTE: Be sure the heads of the caliper bracket (1) insert nuts are facing outward
toward the wheel.
•Attach the hat (7) to the rotor (6) using washers (8) and bolts (9) as shown in Figure 3. 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 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. Slide the rotor/hat assembly onto the spindle. Install three lug nuts (finger tighten)
to keep the rotor/hat assembly in place while continuing with the installation.
•NOTE: Please reference the caution statement at the beginning of the assembly instructions.
Mount the caliper (5) onto the caliper mounting bracket (1) using two bolts (11)and two
washers (12). View the rotor (6) through the top of the caliper (5). The rotor (6) should be
aligned in the center of the caliper (5). If not, loosen the two bolts (11) and adjust the caliper
(5) by using 0.035 inch thick shim washers (10). The shim washers (10) should be placed
between the caliper (5) and the caliper mounting bracket (1). Finger tighten and recheck
alignment. NOTE: The end of the bolt must be flush with or slightly protuding from the head
of the clinch nut. See Figure 5.
Place spare shims (10) between washer and caliper
mounting ear to achieve the proper mounting fastener configuration. Add as many shim
washers (10) as necessary to achieve the correct alignment. Always use the same amount of
shims on both the top and bottom caliper mounting bolts (11). Loosen the two bolts (11) and
apply red Loctite® 271 to bolt threads (11) and torque to 40 ft-lb. Caliper mount bolts may be
safety wired for additional security.
•Install the disc brake pads (13) and secure using cotter pin (14). Repeat this procedure for the
other wheel.
•Remove the two lug nuts that were used to hold the rotor/hat assembly in place during caliper
installation. Install the wheel and lug nuts, torque to OEM specifications.
•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
220-6420, which includes hoses, fittings, etc., all in one package for this application.
•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 4. Safety Wire Diagram
Page 5
END OF BOLT
HEAD
OF BOLT
HEAD
OF BOLT
HEAD
OF BOLT
CORRECT
END OF BOLT IS FLUSH WITH, OR SLIGHTLY
PROTRUDING FROM END OF CLINCH NUT
WRONG
END OF BOLT IS BELOW END OF CLINCH NUT
WRONG
END OF BOLT IS PROTRUDING TOO FAR
FROM END OF CLINCH NUT AND MAY
INTERFERE WITH MOVING PARTS
END OF
CLINCH NUT
END OF
CLINCH NUT
END OF
CLINCH
NUT
END OF BOLT
END OF
BOLT
Figure 5.
Clinch Nut Engagement Diagram