1. Introduction
This manual provides detailed instructions for the proper installation, operation, and maintenance of your Wilwood Forged Dynapro 6 Big Brake System, Model 140-10742. This high-performance brake system is designed for front axle applications, featuring 6-piston calipers and 12.190-inch plain iron rotors to enhance braking capacity and pad performance. Please read this manual thoroughly before beginning any installation or operation to ensure safety and optimal performance.
Figure 1: Assembled Wilwood Forged Dynapro 6 Big Brake System. This image displays the complete brake assembly, including the black 6-piston caliper, the 12.190-inch plain iron rotor, and the hub assembly, ready for installation on a vehicle's front axle.
2. Safety Information
Brake system installation requires mechanical expertise and specialized tools. Improper installation can lead to brake failure, serious injury, or death. If you are not confident in your ability to perform this installation, seek assistance from a qualified automotive technician.
- Always wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
- Ensure the vehicle is securely supported on jack stands on a level surface before beginning work.
- Never work under a vehicle supported only by a jack.
- Use only recommended brake fluid. Mixing different types of brake fluid can cause system damage.
- Properly bleed the brake system after installation to remove all air.
- Perform a thorough test drive in a safe area after installation to verify proper brake function.
3. Components List
Verify that all components listed below are present in your kit before beginning installation. If any parts are missing or damaged, contact Wilwood customer support immediately.
Figure 2: Wilwood Forged Dynapro 6 Big Brake System Kit Contents. This image displays all individual components included in the brake kit, such as calipers, rotors, hats, brake pads, mounting brackets, hubs, bearings, seals, and various fasteners.
- Forged Dynapro 6 Piston Calipers (2)
- 12.190-inch Plain Iron Rotors (2)
- Aluminum Rotor Hats (2)
- Caliper Mounting Brackets (2)
- High-Performance Brake Pads (1 set)
- Hub Assemblies (2)
- Wheel Bearings and Seals (2 sets)
- All necessary mounting hardware (bolts, washers, nuts)
- Brake Lines (if included in specific kit variant)
4. Setup and Installation
Follow these steps carefully for proper installation. Refer to Figure 3 for an exploded view of the assembly.
Figure 3: Exploded Diagram of Wilwood Forged Dynapro 6 Big Brake System. This technical drawing illustrates the individual components and their assembly order, including the existing spindle, hub, rotor, caliper, and mounting hardware with numbered parts for reference.
- Prepare Vehicle: Lift the vehicle and secure it on jack stands. Remove the front wheels and the existing brake components (caliper, rotor, dust shield).
- Install Hub Assembly:
- Clean and inspect the existing spindle (labeled "EXISTING SPINDLE" in Figure 3).
- Install new wheel bearings (7, 8) and seals into the new hub (6). Pack bearings with high-temperature wheel bearing grease.
- Slide the hub assembly onto the spindle. Install the spindle nut (16) and washer (14), then torque to vehicle manufacturer specifications. Secure with a cotter pin (13) or retaining ring (15).
- Assemble Rotor and Hat:
- Attach the rotor hat (9) to the plain iron rotor (12) using the provided hardware (11). Ensure the hat is centered and torqued evenly.
- Mount the assembled rotor and hat onto the hub (6).
- Install Caliper Mounting Bracket:
- Attach the caliper mounting bracket (1) to the existing spindle using the provided bolts (2) and washers (3). Ensure proper alignment and torque to specifications.
- Mount Caliper:
- Install the brake pads (21) into the caliper (17).
- Position the caliper (17) over the rotor and attach it to the caliper mounting bracket (1) using the provided bolts (18) and washers (19). Ensure the caliper is centered over the rotor. Torque bolts to specifications.
- Connect the brake line to the caliper. Use new crush washers and torque the banjo bolt to specifications.
- Bleed Brake System:
- Bleed the entire brake system according to vehicle manufacturer recommendations to remove all air. Start with the caliper furthest from the master cylinder.
- Check Wheel Clearance:
- Before installing wheels, verify adequate clearance between the caliper and the wheel spokes/barrel. Refer to Figure 4 for clearance guidelines.
- Final Checks: Reinstall wheels, lower the vehicle, and re-check all fasteners for proper torque.
Figure 4: Wilwood Wheel Clearance Diagram for Kit P/N 140-10742. This diagram provides critical dimensions for ensuring proper clearance between the caliper and the vehicle's wheel, indicating minimum required space for safe operation.
5. Operating Instructions
5.1 Brake Pad Bed-In Procedure
Properly bedding in new brake pads and rotors is crucial for optimal performance and longevity. Follow these steps:
- Perform 10-12 moderate stops from 60 mph down to 15 mph. Allow approximately 30 seconds between stops for cooling.
- After the last stop, drive for several minutes without applying the brakes to allow the system to cool down gradually.
- Avoid hard braking or prolonged heavy use immediately after the bed-in procedure.
5.2 General Operation
After the bed-in process, your Wilwood brake system is ready for normal operation. Always be aware of your vehicle's braking characteristics and adjust your driving style accordingly. High-performance brake systems may exhibit different pedal feel or noise characteristics compared to stock systems.
6. Maintenance
Regular maintenance ensures the continued safety and performance of your Wilwood brake system.
- Brake Fluid: Check brake fluid level regularly and replace it according to your vehicle manufacturer's recommendations, typically every 1-2 years. Use only DOT 3 or DOT 4 brake fluid as specified.
- Brake Pads: Inspect brake pads for wear every 5,000-10,000 miles or during tire rotations. Replace pads when friction material thickness reaches 2-3mm.
- Rotors: Inspect rotors for cracks, excessive wear, or warping. Rotors should be replaced if they fall below the minimum thickness specification or show signs of damage.
- Caliper and Hardware: Periodically check caliper mounting bolts for proper torque. Inspect brake lines for leaks or damage.
7. Troubleshooting
This section addresses common issues you might encounter with your brake system.
| Symptom | Possible Cause | Solution |
|---|---|---|
| Soft or Spongy Pedal | Air in the brake lines; low brake fluid level. | Bleed the brake system thoroughly; check and top up brake fluid. |
| Excessive Brake Noise (Squealing/Grinding) | New pads/rotors not bedded in; worn pads; foreign material; improper installation. | Perform bed-in procedure; inspect and replace worn pads; clean components; re-check installation. |
| Vibration or Pulsation During Braking | Warped rotors; uneven pad transfer; loose components. | Inspect rotors for runout and replace if necessary; re-bed pads; check all mounting hardware. |
| Reduced Braking Performance | Worn pads/rotors; contaminated pads; brake fluid issues. | Inspect and replace worn components; check for fluid leaks or contamination; ensure proper bed-in. |
If you encounter issues not listed here or if troubleshooting steps do not resolve the problem, contact Wilwood technical support.
8. Specifications
| Feature | Detail |
|---|---|
| Model Number | 140-10742 |
| Brake System Type | Forged Dynapro 6 Big Brake Kit |
| Application | Front Axle |
| Caliper Type | 6-Piston Caliper |
| Rotor Diameter | 12.190 inches |
| Rotor Type | Plain Iron Rotor |
| Caliper Finish | Black Powder Coat |
| Material | Aluminum (caliper), Iron (rotor) |
| Item Weight | Approximately 48 pounds (total package) |
| Assembly Required | Yes |
| Vehicle Service Type | Automobile (Vehicle Specific Fit) |
9. Warranty and Support
For specific warranty information regarding your Wilwood Forged Dynapro 6 Big Brake System, please refer to the documentation included with your purchase or visit the official Wilwood website. Wilwood provides technical support for installation and product-related inquiries.
Manufacturer: WILWOOD
Contact: Refer to Wilwood's official website for current contact information and technical support resources.
