SETTING THE CALIPERS

Now that both rotors have been mounted to the spindles, its time to set the calipers. Test fit the caliper onto the rotor without the brake pads. Fit one side at a time. Slip the retaining bolts into position and tighten them down. Assuming the vehicle is on jacks, move the steering from one end to the other. Check for obstructions. I had to trim some casting flashing from the caliper hose fitting area. The photo shows the area where the flashing was removed. Take time to fit the calipers to each side to clear any obstructions. The old spindle stops will not work with the new caliper brackets, so they will have to be removed. I double nutted the king pin retaining pin to provide a spindle stop.

After the fitting is complete, install the brake pads and remount the calipers. You will have to determine the hose length that fits you application best. Connect the flexible brake hose to its original fitting. You can have brake hoses made up at almost any parts supplier. On the project truck, I have installed a set of donor brackets from a 1980 El Camino. I also pulled the calipers and rotors off the same vehicles. If I had choose to mount these hoses at the original connection, the hoses would be too short.

MOUNTING THE BOOSTER

The next section covers power booster and master cylinder connections. The connection information in this section will be covered in general. I’ll be using the remote booster system as the example.

The old master cylinder is removed, leaving a front and rear brake supply line. Once the booster is in place, a tee is used to connect both lines together. A main feed line is tied into the tee from the booster to complete the supply line plumbing. If you are using a dual reservoir master cylinder/booster mounted under the cab floor in the OEM location or on the firewall, extend and connect each line to the appropriate reservoir port on the master cylinder.

Now to add the proportioning valve and residual pressure check valves. On the supply line for the rear brakes, about 8" down from the tee, the proportioning valve is cut in. This will help us even out the braking on the project truck. Down the same line another 6", a residual pressure check valve is cut in. As shown in the photo, the red RPCV will maintain 10 lb. of residual brake fluid pressure on the rear brake wheel cylinders.

All that is left in this project is the placement and mounting of the master cylinder to the firewall. This project is covered in your brake swing pedal article, don't miss it. CTS