12" Big Brake Kit Installation Instructions

Now that you purchased your Big Brake kit, it is very important to focus on proper installation.  Installation of this kit is not difficult, and does not even require bleeding of brakes (provided that your brake fluid is clear and fresh), but we urge you not to underestimate the importance of proper brake installation -- your life literally depends on it!  This installation process should only be performed by an expert.

What comes with your kit:

(1) quantity 2 -- 12" rotor/aluminum hat combo

(2) quantity 2 -- CNC aluminum black anodized caliper relocation brackets 

(3) quantity 4 -- aluminum black anodized caliper spacers

(4) quantity 4 -- metric socket head bolts (short)

(5) quantity 4 -- metric socket head bolts (long)

Tools Required:

(1) Metric socket heads

(2) Torque wrench (very important)

(3) Feeler gauge (same as used to set valve/cam clearance)

(4) Wire brush

STEP 1

Begin by removing the stock caliper and rotor.  This is a good opportunity to service the caliper by lubing the sliders and inspecting the piston for leaks and corrosion.  Do not hang the caliper by the hydraulic line!  Either hang the caliper from the suspension spring using a rope, or place the caliper on a pedestal so that  no stress is placed on the hydraulic line.

Once the caliper is removed, THOROUGHLY WIRE BRUSH ALL CORROSION FROM THE BACK SIDE OF THE SPINDLE.  FAILURE TO DO SO WILL LEAD TO MISALIGNMENT AND VIBRATION OF THE CALIPER.  SEE PICTURE BELOW.  AGAIN, YOU MUST REMOVE ALL THE CORROSION THE THE SPINDLE MOUNT!  Repeat the wire brush cleaning procedure on the hub at the surface to which the brake disc is mounted. 

STEP 2

Using the longer socket head bolts provided, bolt the caliper relocation bracket to the spindle, torque to 60 ft.lbs., as shown in picture below.  Then install the big brake rotor, securing it to the hub with two bolts.  Tighten the bolts so that the rotor is mounted flush with the hub, but do not over-tighten.

STEP 3

Bolt the caliper to the relocation bracket using shorter socket head bolts provided, torque to 65 ft.lbs.  Note that there is some free play in the caliper positioning.  This free play is important in order to set the proper clearance between the caliper and the outside perimeter of the disc rotor to account for thermal expansion.  Make sure rotor to caliper clearance is approx. 0.040".  The picture below shows a caliper installed.  The gap to measure is defined by the gap between the caliper and the "red" painted zone on the perimeter of the disc brake rotor.

STEP 4

Verify proper installation of rotor/caliper by making sure that the caliper is parallel to the rotor, bolts are properly torqued.  It is a good idea to rotate the rotor to verify that there is no rotor to caliper housing metal-to-metal contact.  If metal-to-metal contact is oberved (other than the brake pads rubbing on the rotor of course) loosen the caliper bolts and reposition the caliper to set the proper rotor to caliper clearance using a feeler gauge as described in STEP 3.

You may also notice that a small part of the brake pad (about 1-2 mm) overhangs the disk.  This is normal as the larger rotors have a larger arc radius then the stock calipers/pads. 

Have fun and enjoy the look and feel of your new big brakes!