Power Disc Brakes Installation - Braking The Habit

With the inner bearing prepared, install the rotor onto the spindle. Notice the shoulder at the base of the spindle has been generously lubed to protect the seal during installation. Rotate the rotor during the seating process to help the seal over the shoulder.

With the rotor seated on the spindle, pack the outer bearing with grease, and then install it. Next, this keyed flat washer goes into place.

To complete the rotor installation, tighten the spindle nut to 15 ft-lb and then back the nut off and retighten hand tight. Add the nut retainer and cotter pin to finish the installation.

Install the single-piston floating caliper onto the caliper mounting bracket using the supplied hardware. Be sure the bleeders are pointing up. You may wish to use a semi-permanent thread locker such as Loctite for the caliper installation.

The brake hoses attach to the caliper using these two solid copper washers. The soft metal assures a perfect seal. A leak is guaranteed if the washers are forgotten.

Attach the other end of the brake hose to the hard lines at the support bracket. It's a good idea to use a line wrench to avoid rounding off the fittings. Some hard lines will require an adapter, which is included in the kit and shown installed here.

Underneath the hood, it's time to pull the old master cylinder. Some preparations must be made to accommodate the new vacuum booster.

The hard brake lines on our car look good, and we're going to save all of them. The OE drum brake junction block has to go, however. Here, it is disconnected before being removed from the car.

We use a right-angle drill adapter to create the required openings for our Master Power vacuum booster. Several existing holes are enlarged, and one new hole is drilled to accommodate the booster mounting studs.