DIY Network

DIY Difficulty Rating for this Project: This job is a medium difficulty project, and will generally require two people. We gave it a difficulty rating of 2 on a 5-point intermediate-level scale. All the parts you'll need come together in the kit. The more complex parts of this project may be dealing with fluids and hoses. If you've done a brake job before, you should have no problem with these upgrades.

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The oversized steel rotors offer enhanced braking ability and are engineered with specially designed slots to allow brake cooling without compromising structural integrity. These are engraved "left" and "right" on the inside surface to ensure proper orientation on the car.

Brake-Kit Installation

Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

• First, review the instructions that come with the kit, and inspect all of your parts. Check to make sure that you have everything that is supposed to come with the kit, and that no parts appear to be damaged.

• Important: Because these specific rotors are directionally slotted and directionally vented, you want to make sure you install each of them on the correct side of the car. The steel rotors are engraved "left" and "right" on the inside surface to ensure proper orientation on the car. The top of the rotor slot should face the back of the car.
  

• Install the caliper-mounting brackets onto the front side of the spindle ears (figure A). Attach these with the nuts and bolts that came with the kit. Tighten them down first with a closed-end wrench, and then go back using a torque wrench to lock down the bolts at 60-foot pounds each.

• Now it's time to add the 12-inch rotors. First, spray both sides of the rotors with brake cleaner, and wipe them down to get rid of any fingerprints or contaminants -- which can cause trouble with new pads.

• Slide the rotor onto the hub (figure B), and secure it with two lug nuts.

  Figure A

  Figure B

  
  

• Next, install the brake pads. The first step is to install the retaining clip onto the inner brake pad (figure C).

• The pads with the clips go into the piston side of the caliper (figure D).

  Figure C

  Figure D

  
  

• Check the fit of the outer brake pad in the caliper to ensure that it fits snugly. If the fit is not snug, the two tabs on the outer pad (figure E) need to be bent downward until the pad is held firmly in the caliper housing.

• You may need to tap the tabs with a hammer to bend them into proper position (figure F).

  Figure E

  Figure F

  
  

• With the pads in place, slide the calipers over the rotor (figure G).

• Install the two slider bolts through the caliper-mounting bracket. First tighten them down, and then torque them to 30-foot pounds.

• Use the banjo bolts and copper washers to connect the other end of the flex house to the caliper (figure H). Torque these to 20-foot pounds.

  Figure G

  Figure H

  
  

• Install the flex house by securing it to the original frame bracket with the clips. Attach the one at the spindle first then connect the one at the other end and connect the factory hard line and tap into place.

• Remove the vacuum cap that was sealing off the hard line and screw the brake line together at the retaining bracket (figure I). You'll need two line wrenches to tighten the lines. Use one wrench on each side, taking care not to round off the brass fittings.

• With all the components in place, check to make sure that there's no interference of moving parts with the flex hose. Turn the steering wheel from lock to lock while an assistant checks the movement of the rotor (figure J). Now just give the rotor a spin to make sure that it turns freely and nothing grabs.

  Figure I

  Figure J

  
  

In the segment that follows, the brake upgrade and servicing continues as Andrew demonstrates how to bleed the big brakes.

Tricked-Out Tech-Speak: A banjo bolt is a specialty bolt that allows fluid to run through it.

RESOURCES :

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

Special Resources for Tricked Out, episode 109

Stainless Steel Brakes Corporation (SSBC)
Website: www.ssbrakes.com

Racing Innovations, Inc.
Website: www.racinginnovations.com

ALT Wheels
Website: www.altwheels.com

The Fusion Zone
Website: www.thefuzionzone.com

GUESTS :

Bill Cummings
Stainless Steel Brakes Corporation (SSBC)
Website: www.ssbrakes.com