Dorman 13894 Oversized Brake Caliper Bolt Instruction Manual

Product Overview

The Dorman 13894 Oversized Brake Caliper Bolt Kit is designed to provide a reliable and cost-effective solution for repairing stripped brake caliper mounting holes in steering knuckles or other components. This innovative bolt is engineered with a slightly larger diameter and a built-in thread-cutting feature, allowing it to create new, secure threads in a damaged hole, thereby eliminating the need for expensive component replacement or complex rethreading procedures.

What's in the Box

• 1 x Dorman 13894 Oversized Brake Caliper Bolt
• 1 x Tube of Thread Locker

Specifications

Setup and Installation

This oversized brake caliper bolt is designed for direct replacement in stripped caliper mounting holes. It features a self-tapping design to create new threads. Always ensure the vehicle is safely supported and the brake system is depressurized before beginning work.

1. Vehicle Preparation: Safely lift and support the vehicle. Remove the wheel and any components necessary to access the brake caliper and its mounting points.
2. Assess Damage: Confirm that the existing caliper mounting hole is stripped. This bolt is intended for holes where the original threads are no longer able to hold torque.
3. Clean the Hole: Thoroughly clean the stripped hole to remove any debris, rust, or old thread locker. Use a wire brush or appropriate cleaner.
4. Apply Thread Locker: Apply a small amount of the provided thread locker to the threads of the Dorman 13894 oversized bolt.
5. Initial Engagement: Carefully align the oversized bolt with the stripped hole. It is crucial to start the bolt straight and not at an angle to ensure proper thread cutting. If possible, use the caliper itself as a guide by installing the other caliper slide bolt first (if applicable) to help maintain alignment.
6. Thread Cutting and Tightening: Slowly and steadily turn the oversized bolt clockwise. The bolt's design will cut new threads as it advances into the stripped hole. Continue tightening until the bolt is fully seated and the caliper is securely mounted.
7. Torque Specification: Torque the bolt to the vehicle manufacturer's specified torque for brake caliper bolts. For many applications, this is around 26 ft/lbs (35 Nm), but always consult your vehicle's service manual for the exact specification. Do not overtighten.
8. Final Checks: Reassemble any removed components, ensuring all fasteners are tightened to specification. Bleed the brake system if any lines were disconnected. Test the brakes in a safe environment before returning the vehicle to service.

Image: The Dorman 13894 Oversized Brake Caliper Bolt shown alongside the included tube of thread locker.

Image: A detailed view of the oversized threads on the Dorman 13894 bolt, designed for cutting new threads.

Operating

Once properly installed and torqued, the Dorman 13894 Oversized Brake Caliper Bolt functions identically to a standard brake caliper bolt, securely holding the brake caliper in place. Its primary function is to restore the integrity of the mounting point, allowing the brake system to operate safely and effectively.

Maintenance

Regular inspection of all brake system components, including caliper mounting bolts, is recommended as part of routine vehicle maintenance. Check for any signs of looseness, corrosion, or damage. If the bolt needs to be removed for future brake service, ensure proper reinstallation and re-torquing, applying new thread locker as necessary.

Troubleshooting

• Bolt Does Not Thread In: Ensure the hole is clean and free of obstructions. Verify that the bolt is aligned perfectly straight. Do not force the bolt; if it binds excessively, the hole may be too severely damaged for this repair, or the alignment is incorrect.
• Bolt Loosens After Installation: This can indicate improper torque during installation, insufficient thread locker, or that the original damage to the mounting hole was too extensive for this type of repair. Re-check torque, apply fresh thread locker, and if the issue persists, consider alternative repair methods such as a professional thread repair insert (e.g., Heli-Coil) or component replacement.
• Brake Noise/Vibration After Installation: Ensure all brake components are correctly reassembled and torqued. Verify that the caliper is not binding and that brake pads are properly seated. This is generally not related to the bolt itself unless it is loose.

Warranty and Support

Dorman Products are manufactured to high-quality standards. For specific warranty information, please refer to the packaging or visit the official Dorman website. For technical support or further assistance, you can visit the Dorman Brand Store on Amazon or contact Dorman customer service directly.