RCR40 MANUAL: Brakes
The brake hardware installation is quite straight forward:
Hang the calipers, Loc-Tite® and torque to specification the mounting bolts. Use Teflon tape on the "L" fittings and install (be careful not to have excess tape get into the brake system). Install the flex hoses
Be careful to route hoses appropriately so as not to contact any moving parts (shocks, wheels, rotors etc).
If your car came equipted with Wilwood calipers, your caliper part numbers will be:
For brake pad options, see the Wilwood guide at the following link: wilwood brake pads
Rear brake pads need to have the inside corners knocked off of the inboard pads prior to installation as shown in above right photo. This is necessary so they do not contact the adapter bracket.
Now simply remove the center bar/tube and slide the pads into place, reinstall center tube. Brake install is done. Of course, do not forget to go back and pressure check all connections after bleeding.
Parking Brake System
The parking brake system consists of:
- Pull handle assembly
- Pull handle bracketry
- Full cable set
- Calipers with pads
- Caliper mounting brackets
First drill the cable mounting holes in the rear bulkhead just above the spinal column from the inside the cabin. The holes should be 1.50" apart and centered over the spinal column. The vertical location should be high enough that the nuts can easily be spun on with out hitting the welds. Be careful not to drill oversized! Once drilled, install the cables from the engine bay side.
Pass the cables through the trailing rod bolt access holes, and feed them toward the rear of the car.
Feed them to the rear of the chassis.
Next, assemble the cable pull clevis to the handle.
Determine which mounting hole you will be using. If you have a center shift vehicle, you will need to use the upper holes to provide the needed clearance for the cables to pass under it. If you have a RH shift car, you will likely want to use the lower mounting holes.
RHD no issue with cables. For LHD route one shift cable above, and one below the handle frame. Do NOT mount the handle assembly at this time. Final position will be determined later.
Install the aluminum spacer block in each caliper. Mount caliper and bracket assembly. You can tighten the adjustment nut down to hold the caliper in place for positional assessment. Clock rotation should be at 3:00.
Reference straight edge dimension to axle center line and then to caliper center to determine 3:00 position.
Again, the 3:00 position is the suggested orientation for this reason and for optimal cable alignment.
While assessing clock rotation, keep in mind that the mounting holes need to be clear of the bearing retension fasteners (Red Arrow). Once you have determined your location, drill and tap for 3/8 x 16 bolt. Start by using a 3/8" drill bit to make a starter hole.
This should be done very carefully to ensure the drilled holes are drilled radially from axle center. Rotate the rotor as needed and use the rotor vanes and rotor brake plate as angular guides for drilling.
Drill to 0.750" deep, tap with 3/8 -16 bottoming tap.
Assemble bracket on upright.
The cable mount bracket needs to be drilled out to fit the cable end. Do this in multiple steps from the back side.
The hole will need to be sized to 0.540"
Using the bracket mark the longitudinal hole positions. The front of the bracket should be adjacent to the chassis weld. The vertical dimension should be 1.750" from the top of the chassis.
Center punch and drill the bracket mounts. Finish size should be 0.250".
Mount the bracket with 0.250" fasteners. Mark the cable through hole. Do so by using a sharpie at the agle the cable will travel.
This hole will need to be 0.750".
When drilling be certain to drill at the angle the cable will pass through. Use the lower trailing arm as a reference.
Route cable above trailing link, then loop around tunnel and up to the rear outboard chassis.
Insert cable into through hole and newly mounted bracket.
Connect cable to actuation arm as shown. Depending on suspension configuration of your car (i.e. wide body), bending the mounting tab to close the angle bracket a little helps with the cable alignment. The 1/4" fastener should not clamp the bracket tight. It should be just loose enough to permit rotation. Double nut the fastener to permit this rotation of the bracket.
Adjust the caliper to have ~ 0.015" pad gap, and lock down the jam nut.
Slide the park brake handle sled forward until the desired cable preload is achieved. Rear mounting holes should be ~ 4.00" from the rear bulkhead weld seam. This will vary depending on rear control arm lengths. Drill and mount parking brake sled. Adjust cable length at sled and caliper actuation arms accordingly to provide desired clamp load.
Don't worry, we did not forget about the brake pedal box. It should be installed at a later time, once other items are installed.