Dorman 13894 Rear Brake Caliper Bolt User Manual

1. Introduction

This manual provides comprehensive instructions for the proper installation and maintenance of the Dorman 13894 Rear Brake Caliper Bolt. This specialized bolt is engineered to provide a reliable solution for securing brake calipers, particularly in cases where original threads may be damaged or stripped. Adherence to these instructions is crucial for ensuring safety and optimal performance.

2. Safety Information

Always prioritize safety when working on vehicle braking systems. Improper installation can lead to serious injury or vehicle damage.

• Ensure the vehicle is securely supported on jack stands before beginning any work.
• Wear appropriate personal protective equipment, including safety glasses and gloves.
• Allow brake components to cool completely before handling.
• If you are unsure about any step, consult a qualified automotive technician.
• Keep children and pets away from the work area.

3. Product Overview

The Dorman 13894 Rear Brake Caliper Bolt is a high-quality replacement component designed for durability and ease of installation. It features an oversized thread pattern specifically engineered to repair stripped or damaged threads in the caliper mounting bracket without requiring extensive re-tapping or replacement of the steering knuckle.

Key Features:

• Includes one bolt.
• Bolt length: 2 3/16 inches.
• Features an oversized thread pattern for repairing stripped threads.
• Requires a 3/8 inch Allen wrench for installation.
• Constructed from durable Stainless Steel.

4. Setup and Installation

Follow these steps carefully for proper installation of the Dorman 13894 Rear Brake Caliper Bolt.

Tools Required:

• 3/8 inch Allen wrench (hex key)
• Brake cleaner
• Torque wrench (recommended)

Installation Procedure:

1. Prepare the Mounting Hole: Thoroughly clean the existing threads in the brake caliper mounting bracket using brake cleaner. Ensure all debris, rust, and old thread locker residue are removed. This is critical for the oversized thread to properly engage.
2. Apply Thread Locker: Apply a small amount of the included medium-strength thread locker (or equivalent) onto the threads of the Dorman 13894 bolt. Ensure even coverage.
3. Initial Engagement: Carefully align the Dorman 13894 bolt with the mounting hole. Begin to thread the bolt by hand to ensure it starts straight. The oversized threads are designed to cut new threads into the damaged hole.
4. Tighten the Bolt: Using a 3/8 inch Allen wrench, slowly and steadily turn the bolt clockwise. Apply consistent forward pressure to help the self-tapping threads engage properly. Do not force the bolt if it binds excessively. If resistance is too high, back the bolt out, clean the threads again, and re-attempt.
5. Torque Specification: Tighten the bolt to the vehicle manufacturer's specified torque for brake caliper bolts. If a specific torque is not available for an oversized repair bolt, consult a professional. Avoid overtightening, as this can strip the new threads or damage the hex slot of the bolt.
6. Cure Time: Allow the thread locker to cure according to its manufacturer's instructions before putting the vehicle into service. This typically takes several hours.

5. Operating

Once installed, the Dorman 13894 Rear Brake Caliper Bolt functions as a critical fastening component, securely holding the brake caliper in place. Its oversized thread design ensures a tight and reliable connection, even in previously damaged mounting holes. Proper installation ensures the brake caliper operates as intended, maintaining safe and effective braking performance.

6. Maintenance

The Dorman 13894 bolt is designed for long-term reliability. Regular maintenance involves periodic inspection of the brake system components.

• During routine brake inspections, visually check the caliper bolts for any signs of looseness, corrosion, or damage.
• Ensure the thread locker is holding securely.
• If any issues are observed, re-torque the bolt to specification or replace if necessary.

7. Troubleshooting

Common Issues and Solutions:

Issue: Bolt not threading or binding during installation.

Possible Cause: Insufficient cleaning of the mounting hole, misalignment, or excessive rust/debris.

Solution: Remove the bolt. Thoroughly clean the mounting hole again with brake cleaner and a wire brush if necessary. Ensure the bolt is perfectly aligned before attempting to thread it in again. Apply steady, even pressure while turning. Do not force the bolt, as this can damage the new threads being cut.

Issue: Hex slot stripping during installation.

Possible Cause: Incorrect Allen wrench size, worn wrench, or excessive torque/force applied too quickly.

Solution: Ensure you are using a high-quality 3/8 inch Allen wrench that fits snugly into the hex slot. Apply steady, rotational force without jerking. If the slot begins to strip, stop immediately. You may need to use a bolt extractor or seek professional assistance if the bolt cannot be removed or tightened.

Issue: Bolt feels loose after installation.

Possible Cause: Insufficient torque, thread locker not cured, or severe damage to the mounting hole.

Solution: Re-check the torque specification and re-tighten if necessary. Ensure adequate cure time for the thread locker. If the bolt still feels loose, the mounting hole may be too severely damaged for this repair bolt, and replacement of the caliper bracket or steering knuckle may be required.

8. Specifications

9. Warranty and Support

For information regarding warranty coverage and technical support for your Dorman 13894 Rear Brake Caliper Bolt, please refer to the official Dorman Products website or contact Dorman customer service directly. Keep your purchase receipt as proof of purchase.

Dorman Products Official Website: www.dormanproducts.com