General Information and Assembly Instructions
•Installation of this kit should only be performed by individuals experienced in the
installation and proper operation of disc brake systems. Prior to any attempt to
install this kit, please check the following to ensure a trouble free installation.
•Inspect the contents of this kit against the parts list to ensure that all
components and hardware are included.
•Make sure this is the correct kit to fit the exact make and model year of
your axle. This kit is designed for direct bolt-on installation to 1997 through
2003 model year Chevrolet C-5 Corvette hubs. 2000-2004 OE C-5, Z06 or
speciality aftermarket wheels. Check wheel clearance diagram.
•Verify your wheel clearance using Figure 2.
•Verify that the factory hub and stud pattern matches the stud hole pattern in the
hats supplied with this kit. Hubs that have been modified with different size
studs or lug patterns may require modifications to the hat that must be
performed by a qualified machinist.
Disassembly
•Disassemble the original equipment front brakes: Raise the front wheels
off the ground and support the front suspension according to the vehicle
manufacturer’s instructions.
•Remove the wheel. Remove the two bolts from the backside of the spindle that
hold the stock caliper mounting bracket and lift off the bracket and stock caliper
as one unit. If space is a problem, you may have to unbolt the stock caliper from the caliper bracket before removal. Save the stock
caliper mounting bracket bolts and washers, they will be utilized during reassembly, then slide off the stock hat and rotor assembly.
•Clean and de-grease the spindles as well as the stock caliper bracket bolts. Remove all nicks or burrs on the spindle snout and threads.
Assembly Instructions (numbers in parenthesis refer to the parts list/diagram on the preceding page):
•The caliper mount bracket assembly (1) should be installed first with clean, dry threads on the mounting bolts. Install the bracket using
the original caliper mount bolts. The bolts will now pass through the spindle from the opposite direction that they were removed (see
Figure 1). The bracket must tighten squarely against the inboard side of the caliper mount bosses on the spindle body. Inspect for
interference from casting irregularities, machining ridges, burrs, etc. Use one thin shim (2) between the bracket and spindle during
initial trial fitting. Later, after the caliper, pad, and rotor alignment has been checked, and any necessary shims have been put in place,
the mount bolts should be coated with red Loctite
®
271 and torqued to 65 ft-lbs.
•Assemble the rotor (3) to the hat (4) with the bolts (6) and washers (5) provided in the
configuration pictured in Figure 1. Be sure all bolts thread in smoothly and are snug. Then,
torque all bolts in an alternating sequence to 85 in-lbs. The rotor mounting bolts (6) must be
lockwired using standard 0.032 inch diameter stainless steel safety wire as shown in Figure 3.
Please refer to Wilwood’s data sheet DS-386 (available at www.wilwood.org/ds386.pdf) for
complete safety wire installation instructions.
•Install the hat and rotor assembly onto the hub. Check to be sure the hat seats squarely
against the hub. The hub must be free from any rust, debris, casting burrs, machining
irregularities, etc. Use several lug nuts to hold the rotor and hat firmly against the hub during
the next phases of the installation and clearance checking procedures.
•Install spacer (11) and one shim (12) over each stud (10) on the radial mount bracket (1). Slide
the caliper (7) in place over the studs and rotors and install the washer (9) and lock nut (8) to
hold the caliper in place. The caliper bleed screws should be pointing up. Snug the lock nuts
(8) and check that the rotor (3) is centered in the caliper (7). Add or subtract .035" shims (2)
as necessary between the mount bracket and the spindle to center the caliper.
BEGIN BY SLIDING THE 0.032"
DIAMETER WIRE THROUGH TWO OF
THE HOLES (LEFT) THAT ARE 180°
APART. TWIST THE WIRE AS
SHOWN (BELOW) USING SAFETY
WIRE PLIERS. NOW SLIDE ONE
WIRE THROUGH TWO OF THE
HOLES (180° APART) AND WRAP THE
OTHER WIRE AROUND THE BOLT.
TWIST THE WIRES TOGETHER TO
FORM A PIGTAIL. SEE DS-386 FOR
COMPLETE DETAILS.
Figure 3. Safety Wire Diagram
FACE OF
STOCK HUB
INSIDE WHEEL PROFILE
(MINIMUM REQUIRED
FOR CLEARANCE)
.30 HAT THICKNESS
REFERENCE
FACE OF WILWOOD HAT
STOCK WHEEL MOUNTING
SURFACE OFFSET
CENTER
LINE OF
WHEEL
1.27 (32,3)
.56 (14,2)
4.86
(123,4)
7.93
(201,4)
7.83
(198,9)
WHEEL STUDS
WILWOOD
ROTOR
CALIPER
Figure 2. Wheel Clearance Diagram
