INSTALLATION INSTRUCTIONS

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1 INSTALLATION INSTRUCTIONS REAR DISC BRAKE CONVERSION KIT A117-1, A S10 PICKUP & BLAZER ASTRO AND SAFARI VAN Thank you for choosing STAINLESS STEEL BRAKES CORPORATION for your braking needs. Pleases take the time to read and carefully follow these instructions to insure the ease of your installation as well as the proper performance of the complete system. Before beginning your installation, please verify you have received all the parts indicated on the packing slip. If you believe anything to be missing or incorrect, please call our Customer Service Department at To assure your installation will go safely and smoothly, have the following items on hand to assist you: JACK & JACK STANDS LUG WRENCH TORQUE WRENCH SOCKET SET BRAKE CLEANER WRENCH SET TUBE WRENCHES MALLET BRAKE FLUID GEAR OIL These kits use the following pads: SSBC#: 1047 Revision 3 3/27/12 FMSI#: D-347 Stainless Steel Brakes Corporation Main Road Clarence, NY Phone: (800) (716) Fax: (716) info@ssbrakes.com

2 NOTE: Part numbers of components are shown in parenthesis. 1) Raise the car until the wheels and tires clear the floor. Support car on jack stands Remove lug nut covers. Remove wheel and tire assembly. 2) Remove drum brake assembly as follows: a) Pull brake drum from assembly. NOTE: If the brake drum will not come off easily, retract shoes by inserting a narrow screw driver through the brake adjusting slot in the backing plate, and disengage the adjusting lever from the adjusting screw. While thus holding the adjusting screw, back off shoes with the adjusting tool. b) Disconnect parking brake cable from actuator and pull out of plate, after compressing retaining clip. c) Disconnect rigid brake line from axle distribution block, making sure not to strip the ferrule nuts. We strongly recommend the use of a tube wrench. BE CAREFUL NOT TO GET BRAKE FLUID ON THE PAINT, IT CAN CAUSE SEVERE DAMAGE! 3) Removing axles and backing plates: a) Remove differential cover and drain all fluid. b) Working through the opening of the case, remove the side gear pinion shaft lock bolt (7mm hex). c) Push the side gear pinion shaft (pin) out. d) Push the axle shafts inward and remove C lock from each inner end of axle shafts. e) Remove axle shafts. f) Remove backing plates, shoes and brake lines from axle, as an assembly, discard parts. 4) Caliper mounting brackets: a) Orient main mounting plate (A2418L) to axle flange so that a centerline through the upper 7/16 holes points in an approximately 1 o clock position (back end up when viewed from the driver s side). b) Secure caliper mounting plate to axle flange using original 3/8-24 cap screw and nuts, installed from the inside to matching holes of the mounting bracket. c) Install two 7/16 x 1-1/2 bolts (0651) from outside into outer holes in mounting plate. Slide one 7/16 x 1/2 long spacer (A2408K) over each bolt and install one caliper (boomerang shaped) mounting strap short (2407-2) on top and one long (2407-3) on the bottom of each plate. (Calipers will be mounted to these straps.) d) Secure assembly with four 7/16-24 elastic stop nuts (2154) and torque to ft-lbs. A117-1, -2 Revision 3 1

3 5) Axle: a) Reinstall axles in reverse manner as removed. Don t forget to install new differential fluid. 6) Rotors: a) Mount rotors (23007AB1A) on axle and temporarily secure with at least one lug nut 7) Caliper Installation: NOTE: BE CAREFUL THAT ALL HYDRAULIC COMPONENTS ARE KEPT CLEAN AND FREE OF DEBRIS INSIDE AND OUT. REMEMBER: DIRT IS THE ENEMY OF HYDRAULIC SYSTEMS, AND WE CANNOT BE RESPONSIBLE FOR ANY SYSTEM FAILURES DUE TO AN UNCLEAN INSTALLATION! a) Calipers are marked left and right, make sure that they are on the proper sides (parking brake spring should be on top). b) Install flex hoses (14335). Attach hose with brass block end to caliper inlet ports using special hollow bolt which includes a bleeder valve (A0725) and one copper washer (2103-M) on each side of block. Torque bolt to ft/lbs. c) Place caliper (2424R) over left side rotor (2424L right side) and secure to mounting bracket assembly with two 12mm-1 special bolts (0625). Torque to ft/lbs. NOTE: DO NOT ADVANCE CALIPER PISTONS WITH PARKING BRAKE LEVERS. However, if a piston has been extended too far, turn piston back into caliper; we recommend special to KD-2545, available at most parts stores. 8) Brake Lines: a) Replace original rear axle rigid lines with new spring covered rigid lines (C14372 & 3; C14372 on passenger side), hand bend to shape similar to original brake line and secure to axle housing with original clips. Connect fittings to original axle junction block an one end and flex line (14335) at other end. Use at least two wrenches; one a tube wrench. 9) Parking Brake: a) Feed parking brake cables through both support ( L ) brackets (1209-1) and through holes in caliper near parking brake lever. Assure that cable housing clips engage and lock into L brackets. b) Engage parking brake cables into caliper parking brake levers. c) Shorten passenger side parking brake cable approximately 1 by turning cable adjusting nut counter-clock wise. d) Parking brakes should have a slight drag after two to three clicks of foot pedal and caliper parking brake levers should return to their release stops when the parking brake pedal is disengaged. e) Test several times to assure that operation is normal and that the car can t move even if engine power is supplied when parking brake is engaged. A117-1, -2 Revision 3 2

4 10) Proportioning valve: THIS MODIFICATION SHOULD ONLY BE PERFORMED ON 1996 AND EARLIER TRUCKS. ON 1997 AND LATER VEHICLES, THE PROPORTIONING IS CONTROLLED BY THE ABS SYSTEM AND REQUIRE NO MODIFICATION. IF YOU HAVE A 1997 OR LATER TRUCK WITH THE ABS BLOCK DO NOT ATTEMPT ANY MODIFICATION. THE ABS SYSTEM WILL COMPENSATE FOR THE INCREASED REAR BRAKING POWER ELECTRONICALLY. a) Open hood and locate factory distribution block/proportioning (sometimes called combination valve) located below and forward of master cylinder. b) Unscrew hex plug from front side of block. Be careful - it is spring loaded. Inside the unit is a spring and piston. Pull out spring and piston (with needle nose pliers). Discard spring and U cup seal from piston. c) Reassemble block by inserting only the bare piston. Screw plug back into block. BE SURE TO LEAVE OUT SPRING AND U CUP SEAL. BUT SEAL UNDER PLUS MUST REMAIN. 11) Filling and Bleeding the System: NOTE: When bleeding rear system, use bleeder screws on top of special banjo bolts instead of normal caliper bleeder screws! a) It is advisable to replace brake fluid if the color is brown or muddy. This condition is due to water that has been absorbed by the fluid and which will eventually corrode the brake lines and master cylinder, plus possibly creating a vapor lock under extreme braking conditions. Flush system with clean brake fluid and replace with a good grade of disc brake fluid (DOT 3 or 4 Glycol base) available from our company. Silicone fluid will not absorb water, cannot damage paint and maintains its viscosity over a large temperature range. b) If pressure bleeding is employed, the correct air pressure regulator setting is psi (max). c) Tapping the caliper with a rawhide mallet as fluid is flowing out of the bleeder screw may assist in obtaining a better bleed job. d) With bleeders closed and system bled, a hard pedal should be experienced so that at full application the toe of your left foot can still be placed between the bottom of the pedal and the floor. 1) Power brake cars will experience a drop off of the pedal when the engine is started. This is a normal condition and signifies that the booster is working correctly. 12) Final Assembly and Inspection: a) Take lug nuts off studs. b) Mount wheel, torque lug nuts to factory specifications. c) Double check to assure that there are no interferences. A117-1, -2 Revision 3 3

5 d) Lower vehicle to ground. e) Test drive vehicle in an open area away from traffic to assure proper operation and apply brakes cautiously to seat pads. DO NOT USE ANTI-SQUEAK ADHESIVE ON BACK OF PADS. THIS WILL DEGRADE THE PERFORMANCE OF THE CALIPER! DO NOT DRIVE CAR UNTIL BRAKES STOP THE CAR WITHOUT A SPONGY FEELING. INITIAL BRAKING TESTS SHOULD BE DONE IN A SAFE OPEN AREA. IF BRAKES DO NOT OPERATE CORRECTLY, CONTACT ONE OF OUR TECHNICIANS FOR ASSISTANCE. BRAKING TESTS SHOULD ALWAYS BE DONE IN A SAFE OPEN AREA! NOTE: For frequently asked questions and technical reference information please visit the tech section of our website at TECH LINE -- If technical help is required, please call Now enjoy true braking performance!! A117-1, -2 Revision 3 4

6 A117-1, -2 Revision 3 5

7 WHEEL MOUNTING SURFACE C L DIMENSIONS ARE IN INCHES TEMPLATE NO. T-038 DO NOT SCALE DRAWING SSBC STAINLESS STEEL BRAKE CORP. CLARENCE, NEW YORK Ph: / ~ Fx: REV

8 C L WHEEL MOUNTING SURFACE DIMENSIONS ARE IN INCHES TEMPLATE NO. T-042 DO NOT SCALE DRAWING SSBC STAINLESS STEEL BRAKE CORP. CLARENCE, NEW YORK Ph: / ~ Fx: REV

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