| Disc-Brake Conversion: Introduction and Parts |
From "Weekend Mechanic"
episode WKM-210 |
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In this episode, Weekend Mechanic Bruce Bonebrake conducts a disc-brake conversion on a classic American muscle-car. He replaces the front drum-brakes on a 1967 GTO with a new disc-brake kit. The problem: Drum brakes (figure A) just don't offer the performance of today's modern disc brakes. Our project car -- a 1967 GTO -- has plenty of horsepower, but leaves something to be desired in terms of stopping power. In order to enhance both safety and driving performance, the old disc brakes are replaced with new disc brakes (figure B). DIY Difficulty Rating for Repair: This job is not as difficult or complex as many people might think. We gave it a difficulty rating of 3 on a 5-point intermediate-level scale. The time required depends on the condition and specifics of your vehicle. Our total work time for this vehicle was about 9 hours. Allow yourself a whole weekend to allow for any possible complications. Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of brake-conversion kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts. Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools. Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components. In addition to standard auto-mechanic's tools, some of the specialty tools that will be needed for this project include bench bleed-kit, tubing cutter, caliper-bleeding kit, flaring tool and bearing packer. An air-ratchet is optional, but will help speed the assembly process. Introduction: Disc-Brakes vs. Drum Brakes - The brake-conversion kit (figure C) used in our demonstration cost around $500. It comes with all of the parts necessary for the upgrade.
- The disc-brake rotor is one of the main components in the kit. This rotor is equipped with a front and back-plate assembly, with cooling fins in the center (figure D).
- This particular rotor comes in a two-piece configuration. In addition to the aforementioned the rotor-plate assembly, it comes with a separate machined-aluminum rotor-hub assembly (figure E). In addition to the main hub, it includes bearing races (already installed), bearings and grease-seals. The hub and plate assemblies fit together and are secured with studs.
- These components will replace the front-brake drum (figure F) that were the standard when this car was new.
- The brake drum is made of aluminum and steel. The hub assembly is integrated into the inner side of the drum (figure G).
- Another part of the disc-brake upgrade is the disc-brake caliper assembly (figure H). Calipers are typically available as "loaded" or "unloaded." Loaded calipers come complete with disc-pads and mounting hardware. Unloaded calipers don't include the pads. Purchase unloaded calipers only if you already have some spare brake pads on-hand that are compatible with the new disc brakes.
- The caliper attaches to the vehicle by means of a specially made bracket. The machined bracket has pre-drilled holes for bolting onto the vehicle. The caliper attaches to the bracket by means mounting pins (figure I). Once installed and functioning, the caliper applies pressure that brings the pads into contact with the rotor, thereby stopping the vehicle.
- The brake caliper assembly essentially replaces the old brake-shoe assembly ( figure J) of the old brake system.
- In addition to these mechanical parts, the braking system also includes a hydraulic component. The brake master-cylinder that's presently on the car is not adequate to handle the new brake system. The new combination of front disc-brakes and rear drum-brakes requires more brake fluid than ordinary drum brakes. The old master cylinder will be replaced with a larger one (figure K).
- New brake hoses (figure L) will also be installed as part of the beefier brake hydraulic system.
In the segment that follows, the old front-brakes will be removed from the car.
RESOURCES :
The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books
Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896
Automotive Brakes and Antilock Braking Systems
Model: 0314028382
Author: Kalton C. Lahue
(1995)
To order this title from Amazon.com, click here.
Delmar Learning
Brake Handbook
Model: 0895862328
Author: Fred Puhn
(1985)
Order this book from Amazon.com.
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