Wilwood W6A Big Brake Truck Front Brake Kit - Manual (Page 4)

Assembly Instructions (numbers in parenthesis refer to the part list/diagram on the
preceding page):
•The caliper mount bracket assembly (1) should be installed first with clean, dry
threads on the mounting bolts. Install the bracket on the outboard side of the
spindle by sliding the original OEM bolt through the OEM mounting ear bolt hole
from the backside, through washer (2) and into the bracket (1). The bracket must
tighten squarely against the outboard side of the caliper mount bosses on the
spindle. Inspect for interference from casting irregularities, machining ridges,
burrs, etc. Use one thin shim (2) between the bracket and spindle during initial
trial fitting.
•With the larger I.D. side of the rotor (3) facing away from the hat (4), bolt rotor (3)
to hat (4) through the backside of the rotor using washers (5) and bolts (6). Using
an alternating sequence, apply red Loctite® 271 to the threads and torque bolts
to 140 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.
•Install the hat and rotor assembly onto the spindle. 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 (1). Slide the caliper (7)
in place over the studs and rotor 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 .029" shims (2) as necessary
between the caliper mount bracket (1) and the caliper mount bosses on the spindle to center
the caliper (7).
•Remove the two caliper pad retaining pins from the caliper (1) by popping out the pin retaining
clips and sliding out the pins. 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 pad retaining pins and secure using the pin
retaining clips.
•Remove the lug nuts that were holding the hat/rotor in place. Install the wheel and torque the lug nuts to manufacturer’s specification.
Check to see that the wheel rotates freely without interference.
•Once all clearances have been checked, remove the wheel, caliper and rotor from the spindle and hub. Secure the caliper mounting
bracket (1) to the spindle using red Loctite ® 271 on the bolt threads. Torque the bolts to manufacturer’s specifications. Reinstall the
rotor 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 47 ft-lbs.
•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 220-8998
(1999-2006) and P/N 220-10979 (2007-2011), 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.
•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.
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 4. Safety Wire Diagram
Page 4
LATE MODEL SPINDLES MAY REQUIRE
MACHINING (BLACK AREA) WITH A
GRINDING WHEEL TO ALLOW THE
WILWOOD CALIPER BRACKET TO
FIT. SMOOTH THE AREA AT THE
CASTING PARTING LINE AT THE
ORIGINAL CALIPER MOUNT TAB OR
EAR, REMOVING ONLY ENOUGHT MATERIAL FOR
THE WILWOOD CALIPER BRACKET (1) TO FIT FLUSH
AND SQUARE TO THE SPINDLE AND ALLOW MOUNT
ATTACHMENT BOLTS (2) TO ALIGN AND THREAD
WITHOUT BINDING
Figure 3. Machining Diagram