Wilwood 120-10936 D52 Caliper Instruction Manual

1. Introduction

This manual provides essential information for the proper installation, operation, and maintenance of your Wilwood 120-10936 D52 Caliper. Please read this manual thoroughly before proceeding with any procedures to ensure safe and effective use.

2. Product Overview

The Wilwood D52 caliper is designed as a direct bolt-on 2-piston replacement for factory original single calipers found on many 1968-1996 GM Passenger Vehicles and Trucks. It features forged billet aluminum bodies, stainless steel pistons, and competition-style high-temperature seals. This design aims to prevent common issues such as rust, bore pitting, and seal failures associated with original equipment calipers. The D52 caliper offers performance benefits and weight savings.

Figure 1: Wilwood 120-10936 D52 Caliper. This image displays the anodized gray finish and overall design of the caliper.

3. Key Features

• Direct Bolt-on Replacement: Engineered for easy installation on many 1968-1996 GM Passenger Vehicles and Trucks.
• Two-Piston Design: Utilizes two pistons for improved braking performance compared to single-piston factory units.
• Forged Billet Aluminum Bodies: Provides strength, durability, and significant weight reduction.
• Stainless Steel Pistons: Resists corrosion and wear, contributing to longer service life.
• High-Temperature Seals: Competition-style seals designed for reliability under demanding conditions.
• Anodized Gray Finish: Durable surface treatment for corrosion resistance and aesthetic appeal.
• Piston Configuration: Features 2.00" and 2.00" pistons, compatible with 1.28" disc thickness.

4. Installation

Installation of brake components requires mechanical expertise and specialized tools. If you are not confident in your ability to perform this installation, it is recommended to seek assistance from a qualified automotive technician.

4.1 Pre-Installation Checks

• Verify that the caliper model 120-10936 is compatible with your vehicle's make, model, and year, specifically for 1968-1996 GM Passenger Vehicles and Trucks.
• Ensure all necessary components are present and undamaged before beginning installation.
• Confirm disc thickness is 1.28 inches for proper fitment.

4.2 General Installation Steps (Consult a service manual for detailed vehicle-specific instructions)

1. Safely lift and support the vehicle. Remove the wheel.
2. Carefully remove the existing brake caliper, brake pads, and rotor.
3. Clean the mounting surface on the vehicle's spindle or axle.
4. Mount the new Wilwood D52 caliper onto the vehicle using appropriate hardware and torque specifications.
5. Install new brake pads (sold separately) into the caliper.
6. Install the brake rotor.
7. Connect the brake line to the caliper's inlet fitting (7/16-20 Banjo). Ensure a proper seal.
8. Bleed the brake system thoroughly to remove all air.
9. Reinstall the wheel and lower the vehicle.
10. Perform a test drive in a safe area to confirm proper brake function.

Figure 2: Technical drawing of the Wilwood D52 Caliper. This diagram provides critical dimensions such as mount center, mount height, mount offset, and disc diameter/width compatibility. It also indicates the inlet fitting type (7/16-20 Banjo).

5. Operation

Once properly installed and bled, the Wilwood D52 calipers operate as part of your vehicle's hydraulic braking system. Depressing the brake pedal applies hydraulic pressure, forcing the caliper pistons to clamp the brake pads against the rotor, generating friction to slow or stop the vehicle.

5.1 Break-in Procedure

New brake pads and rotors require a proper break-in (bedding-in) procedure to achieve optimal performance and longevity. Consult the brake pad manufacturer's recommendations for specific break-in instructions. Generally, this involves a series of moderate stops from increasing speeds, allowing the brakes to cool between cycles, to properly transfer pad material to the rotor surface.

6. Maintenance

Regular inspection and maintenance are crucial for the safe and reliable operation of your braking system.

• Brake Fluid: Check brake fluid level regularly and replace according to your vehicle manufacturer's recommendations. Use only DOT 3 or DOT 4 brake fluid as specified.
• Brake Pads: Inspect brake pads for wear during routine service. Replace pads when they reach their minimum thickness specification.
• Caliper Inspection: Periodically inspect the calipers for any signs of leaks, damage, or unusual wear. Check the condition of the brake lines and fittings.
• Cleaning: Keep calipers clean from excessive brake dust and road grime. Use appropriate brake cleaner if necessary.

7. Troubleshooting

This section addresses common issues that may arise with brake calipers. For complex problems, consult a qualified mechanic.

8. Specifications

9. Warranty and Support

For specific warranty information, please refer to the official Wilwood Brakes website or contact their customer support directly. General return policies for this product state that it is not returnable if it has been assembled, installed, used, or damaged. In case of a warranty issue, the manufacturer will work directly with the buyer to resolve it.

For technical assistance or further inquiries, please contact Wilwood Brakes customer service.