DIY Network

'66 El Camino: Rear Suspension and Brakes From "Resto Rides" episode DRRD-101

Andrew Totolos installs the new rear brakes on the '66 El Camino.

In this five-part DIY series Andrew Totolos, with some assistance from fellow car-enthusiast Christie D'Amore, brings a 1966 El Camino into the 21st century.

Now that the front suspension has been revamped, it's time to work on the rear suspension. Andrew and Christie's work to rebuild the rear suspension includes installing new disc brakes.

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Materials and tools:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), the essential tools required for this phase of the project are listed below.

new springs
new rear disc brakes
sway bars
trailing arms
lubricant for differential
floor jack and jack stands
cherry picker

Note: This is a summary of steps included in the restoration procedures shown in this episode of Resto Rides. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

Safety Alert: As a standard safety precaution, don't rely solely on a jack to support the weight of a vehicle. When using a jack to access or work beneath a vehicle, always use jack stands for support. Make sure that the jack and stands that you use are rated for the weight and type of your vehicle.

Safety Alert: Always wear eye protection and follow proper safety precautions when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.

Rear Suspension and Rear Brakes Conversion

The basic steps in this procedure, as seen in episode 101 of Resto Rides, are summarized below:

• Put the car up on jack stands so the rear wheels can be removed and you can roll underneath the car for a better vantage point.

• Because the entire rear suspension is being rebuilt, it's best to pull out the entire rear end of the car. Disconnect the parking brake lines first, and then the brake lines up top.

• Once the brake lines have been released, undo the shocks and then continue on by unbolting the rear end. Removing the bolts from the upper trailing arms is difficult, so it helps to have a helper close by.
  

  	Removing the brake caliper
  	Installing the bracket for the rear brakes

• Lower the rear axle from the car, remove the bolts from the lower trailing arms, and work patiently until you can get the whole suspension out of the car.
  Now that the rear end is out, place it on a workbench to begin work on rebuilding the suspension.

• Remove the differential cover. Once the differential is supported safely on a table, remove the cover to let the gear oil drain.

• While the gear oil drains, pull the caliper brackets off the new rear disc brakes. 2cb

• Once the gear oil has drained loosen the retaining bolt and pull out the spider cross pin. Use a magnet to remove the retaining pins so the axels can slide right out.

• Next, the backing plates are removed. Undo the brake line connection at the top of the housing and pull them off with the remainder of the drum brake assembly.

• After the rear brakes are removed, unbolt the trailing arms all around and pull off the old coil springs.

• Since the new disc brakes are thicker than the old drum brakes pound out the old wheel studs and then use the old drum to support the hub while pounding in the new longer studs.

• The disc brake brackets bolt on where the old drum backing plates were removed. Slide in the axels, and replace the C-clips and the pin and tighten up the locking bolt. 2cc
  

  	Reinstalling the caliper
  	Installing the upper trailing arm
  	Installing the rear shocks
  	Installing the rear springs
  	Connecting the rear brake lines

• Mount the calipers by tightening the two bolts that hold them to the brackets. 2cd

• Once the new brakes are on scrape off the old differential gasket, and reinstall the new gasket with a cover to seal it up.

• Fill the differential with clean lubricant.

• Install the new lower trailing arms.

• Next, install some larger shock mounts to further strengthen the rear end of the car. Bolt the lowered sports strings into place.

• Install the new upper trailing arms.

• After the upper trailing arms are bolted up use a cherry picker and the floor jack to move the rear end back under the car. It might be a little difficult to maneuver it around the frame and the exhaust. Be patient and let the jack do the lifting while guiding it into place.

• Once the rear end is positioned, bolt in the trailing arms along with a new set of chassis braces to eliminate flex in the car's frame. 2ce

• After the fresh brakes are bolted into the top mounts jack up the rear end until the bottom mounts are close enough to meet up with the shocks. Tighten them down.

• Installing a sway bar in the back of the car will keep the car from leaning in the corners. Tighten down the four bolts on the lower trailing arms, and they're good to go.

• Weld the mounting brackets for the new disc brakes up into the car.

• Once the brackets are in hook up the soft lines to the calipers.

• Attach the parking brake cables to complete the rear suspension and brake conversion.

RESOURCES :

Special resources for DIY's Resto Rides 100 series: 1966 El Camino

Original Parts Group, Inc.
www.opgi.com

Husky Tools
www.huskytools.com

Rick's Hot Rod Shop
www.rickshotrodshop.com

Vintage Air, Inc.
www.vintageair.com

Fuel Injection Specialties
www.fuelinjection.com

Lokar
www.lokar.com

K & N Engineering
www.knfilters.com

Nordskog Performance Products
www.nordskogperformance.net