INSTALLATION INSTRUCTIONS FOR PL510 REAR BRAKE KITS
WITH PARKING BRAKE

NOTE: IF YOU DON'T HAVE THE CORRECT TOOLS OR SKILLS TO BE INSTALLING THIS KIT, HAVE A PROFESSIONAL MECHANIC DO THE INSTALLATION.  PROPERLY OPERATING BRAKES ARE EXTREMELY IMPORTANT FOR THE SAFE OPERATION OF THE VEHICLE!

(1) JACK UP CAR.  SUPPORT ON JACK STANDS PER MANUFACTURERS RECOMMENDATIONS.  REMOVE WHEELS.

(2) REMOVE BRAKE DRUMS, SHOES, WHEEL CYLINDERS, AND HARDWARE.  AT THIS TIME THE BACKING PLATE NEEDS TO BE REMOVED ALSO.  THIS CAN BE DONE EITHER BY CUTTING IT OFF OR BY REMOVING THE STUB AXLE AND UNBOLTING THE BACKING PLATE.  NOTE:  IF YOU REMOVE THE STUB AXLE, BE SURE TO FOLLOW ALL MANUFACTURES RECOMENDATIONS FOR REMOVAL AND REINSTALLATION.  SINCE THE CALIPER MOUNTING BRACKET ONLY UTILIZES THREE BOLTS, THE STUB AXLE ONLY NEEDS TO BE REMOVED IF YOU WANT TO SAVE THE BACKING PLATE OR IF THE WHEEL BEARINGS NEED REPLACEMENT.  IF THE BACKING PLATE IS CUT OFF BE SURE NOT TO DAMAGE THE MOUNTING SURFACE OF THE CONTROL ARM.

(3) CLEAN THE CONTROL ARM MOUNTING SURFACE OF DIRT RUST AND BURRS.  BOLT THE BRACKET ON USING THE 10mm BOLTS, FLAT WASHERS, AND LOCK WASHERS PROVIDED.

(4) SLIDE THE BRAKE ROTOR OVER THE STUB AXLE.  BE SURE IT SITS FLAT ON THE FACE OF THE AXLE.  SOMETIMES THERE ARE DENTS OR EXCESSIVE RUST BUILD-UP ON THE REGISTER WHICH WILL NEED T BE CLEANED OFF.

(5) BEFORE INSTALLING THE BRACKET TO THE CONTROL ARM, BOLT THE 416-9243 BRACKET TO THE MAIN CALIPER BRACKET USING (4) OF THE 1-1/4" LONG COARSE THREAD BOLTS, THICK FLAT WASHERS, AND LOCK WASHERS.  THE RAISED STANDOFF GOES AGAINST THE MAIN BRACKET TOWARDS THE CAR CENTERLINE.

(6) BOLT THE DYNAPRO SINGLE HYDRAULIC CALIPER TO THE BRACKET USING USING (4) OF THE SUPPLIED 1-1/4" LONG COARSE THREAD BOLTS, THICK FLAT WASHERS, AND LOCK WASHERS.  NOW IS A GOOD TIME TO CHECK THE WHEEL FIT.  IT MAY BE NECESSARY TO GRIND THE CALIPER TO OBTAIN CLEARANCE.  IF THIS IS NECESSARY IT MAY BE EASIER TO CHECK THE FIT WITHOUT THE ROTOR INSTALLED.  ALSO SOMETIMES THE ADDITION OF A 1/4" OR 1/2" WHEEL SPACER MAY ELIMINATE THE NEED FOR GRINDING THE CALIPER.  CERTAIN WHEELS, SUCH AS LIBRES ARE VERY LIMITED ON INTERNAL CLEARANCE.

(7) IF THERE IS NO INTERFERENCE WITH THIS CALIPER, INSTALL THE MC4 CALIPER TO THE BRACKET USING THE SUPPLIED 1" LONG FINE THREAD BOLTS, FLAT WASHERS, AND LOCK WASHERS.  THERE IS AN ALUMINUM PAD SPACER IN THE CALIPER.  THAT SHOULD BE ON THE VERY OUTSIDE OF THE CALIPER.  RECHECK THE WHEEL CLEARANCE TO BE SURE NOTHING IS RUBBING OR KEEPING THE WHEEL FROM TURNING FREELY.

(8) ONCE IT IS DETERMINED THAT THERE IS NO INTERFERENCE WITH THE WHEEL INSTALL THE BRAKE PADS IN THE DYNAPRO SINGLE CALIPER.

(9) NOW THAT THE CALIPERS ARE INSTALLED ON BOTH SIDES OF THE CAR, THE CABLES CAN BE INSTALLED. NOTE, YOU WILL BE USING THE STOCK CABLE FROM THE FRONT OF THE CAR TO WHERE IT SPLITS UNDERNEATH, AS WELL AS THE BRACKET THAT CONNECTS THE STOCK CABLES.   YOU WILL NEED TO DRILL THE HOLE IN THE BRACKET ON THE BOTTOM OF THE CONTROL ARM TO 3/4" DIAMETER.  THIS IS THE BRACKET THAT HELD THE STOCK CABLE.  OPENING THIS HOLE UP ALLOWS YOU TO RUN THE CABLE THROUGH THIS BRACKET.

(10) THE CABLES ARE LABELED RIGHT HAND AND LEFT HAND.  THE CABLE WITH THE 6MM ROD ON THE END IS THE LEFT HAND (DRIVERS SIDE).  TO INSTALL THE CABLES, FIRST PUT THE END WITH THE BARREL UNTO THE ACTUATION ARM ON THE MC4 CALIPER.  YOU CAN THEN RUN IT THROUGH THE FIXED ARM AND SECURE IT WITH THE PROVDED C-CLIP.  NOW RUN IT DOWN AND THROUGH THE HOLE YOU OPENED UP BEFORE.  RUN IT THROUGH THE STOCK HOLES ON THE CROSSMEMBER AND SECURE THIS END WITH THE PROVIDED C-CLIP.

(11) RUN THE THREADED END OF THE NEW LH CABLE THROUGH THE BELL CRANK AND THREAD THE STOCK BRACKET THAT YOU SAVED ONTO THE END.  YOU PROBABLY WILL NOT WANT TO THREAD THE ROD TOO FAR INTO THE BRACKET AT THIS POINT.  THE CABLE ON THE RIGHT HAND SIDE (PASSENGER SIDE) IS INSTALLED THE SAME WAY.  THE BALL ON THE END GOES INTO THE OPPOSITE SIDE OF THE THREADED BRACKET.  YOU'LL SEE WHY YOU DID NOT THREAD THE ROD IN VERY FAR.  IT MAKES IT MUCH EASIER TO GET THE BALL END ATTACHED TO THE BRACKET.

(12) YOU CAN NOW THREAD THE ROD INTO THE BRACKET TO TIGHTEN UP THE CABLES ACROSS THE BACK OF THE CAR.  TIGHTEN IT UNTIL YOU CAN PULL THE CABLE INSIDE THE CAR AND LOCK UP THE BRAKE ROTOR.  OBVIOUSLY, YOU DON'T WANT TO TIGHTEN IT SO MUCH THAT THE PADS ON THE MC4 CALIPER DRAG OR LOCK THE REAR ROTORS UP WHEN THE FRONT TO REAR CABLE IS RELAXED.

(13) NOW INSTALL THE SUPPLIED FITTING INTO THE CALIPER USING TEFLON TAPE, AND RUN A BRAKE LINE TO THE CALIPER.  WE USUALLY MAKE UP A -3 HARD LINE  FOR THIS, BUT A -3 FLEX LINE CAN BE RUN AS WELL.

(14) BLEED THE BRAKES AND CHECK FOR LEAKS.

(15) REINSTALL THE WHEEL AND LOWER THE CAR.

 

Warning do not drive on untested brakes.  Brakes must be tested after installation or maintenance.

MINIMUM TEST PROCEDURE

Make sure pedal is firm: Hold firm pressure on pedal for several minutes, it should remain in position without sinking. If pedal sinks towards the floor, check the system for leaks. do not drive vehicle if pedal does not stay firm or can be pushed to the floor with normal pressure.

At very low speed (2 to 5) mph apply brakes hard several times.  Remove the wheels and check the that the components are not touching rubbing or leaking.

Carefully examine all brake components brake lines and fittings for leaks and interference.

Make sure there is no interference with wheels or suspension components.

Drive vehicle at low speed (15 to 20) mph make moderate and hard stops.  Brakes should feel normal and positive.  Again checks for leaks and interference. 

Before using the parking brake, be sure to test it where, if is not working, you will not do any damage to your car, someone else's property, or someone else!

When parking on a hill, make sure you turn your front wheels such that the curb will stop the car from rolling away if there is a failure in the brake system.  Heading up hill, turn the wheels away from the curb.  Heading down hill, turn the wheels into the curb.  If there is no curb or anything to stop the car if it starts to roll, use the same procedure.

Always test the vehicle in a safe place where there is no danger to or from other people or vehicles.

Always wear seat belts and make use of all safety equipment.