Wilwood Disc Brakes 140-8230 User manual

ASSEMBLY INSTRUCTIONS
FOR
SUPERLITE 6 BIG BRAKE FRONT HAT KIT
WITH 14 INCH DIAMETER VENTED ROTOR
1997 - 2004 CHEVROLET C-5 CORVETTE(1)
PART NUMBER
140-8230*
FOR OFF ROAD USE ONLY
BEFORE OPERATING VEHICLE, TEST THE BRAKES UNDER CONTROLLED CONDITIONS. MAKE SEVERAL STOPS
IN A SAFE AREA FROM LOW SPEEDS AND GRADUALLY WORK UP TO RACING SPEEDS. DO NOT RACE ON
UNVESTED BRAKES! ALWAYS UTILIZE SAFETY RESTRAINT SYSTEMS WHILE OPERATING VEHICLE.
IMPORTANT
READ DISCLAIMER OF WARRANTY INCLUDED IN THE KIT.
WARNING: Some cleaners may stain or remove the finish on brake system components. Test the
cleaner on a hidden portion of the component before general use.
(1) FITS 2000-2003 OE C-5, Z06 AND SPECIALITY AFTERMARKET WHEELS, CHECK WHEEL CLEARANCE DIAGRAM, FIGURE 2
*DRILLED SRP ROTORS AVAILABLE; ADD -”D” TO END OF PART NUMBER WHEN ORDERING
WARNING
INSTALLATION OF THIS KIT SHOULD ONLYBE PERFORMED BY PERSONS EXPERIENCED IN THE
INSTALLATIONAND PROPER OPERATION OF DISC BRAKE SYSTEMS. IT IS THE RESPONSIBILITY OF
THE PERSON INSTALLING ANY BRAKE COMPONENT OR KIT TO DETERMINE THE SUITABILITY OF
THE COMPONENT OR KIT FOR THAT PARTICULAR APPLICATION.
RACING EQUIPMENT AND BRAKES MUST BE MAINTAINED AND SHOULD BE CHECKED REGULARLY
FOR FATIGUE, DAMAGE AND WEAR.

Exploded Assembly Diagram and Parts List
5
GT ASYMMETRICAL GROOVE
PATTERN ROTOR
6
2
1
12
11
10
9
EXISTING
HUB
ASSEMBLY
ORIGINAL OEM BOLT AN
D
WASHER REINSTALLED
FROM THE BACK SIDE
43
7
13
8
SRP ROTOR
6PISTON
PISTON
Figure 1. Typical Installation Configuration
1
2
3
3A
4
5
6
7
8
9
10
11
12
13
13A
2
6
2
2
2
24
24
2
4
4
4
4
16
4
4
250-8133
240-8127
160-8023/24
160-8025/26
170-8073
240-2509
230-6737
120-8000/01-RS
230-6001
240-2510
230-6231
300-7639
240-1159
15E-6707
15Q-6828
Bracket, Caliper Mounting
Washer Flat, 1.050 inch
GT Rotor - 1.25” X 14.00” Dia, 12 x 9.18” Bolt Circle (one each, right and left)
Rotor, SRP Drilled and Slotted (one each, right and left)
Hat
Washer, 1/2 inch
Bolt, 1/4-20 x 1.00 Long, 12 Point Stainless
Caliper, Billet Superlite 6R
Nut, Self-Locking Hex Head
Washer, Flat, 5/8 inch
Stud, 3/8-16 x 3/8-24 x 3.15 long (pre installed in bracket)
Spacer, .42” Long
Washer, Flat, 7/8 inch
Pad, Polymatrix “E” Compound, GT Rotor Kit
Pad, PolyMatrix “Q” Compound, SRP Rotor Kit
ITEM NO. PART NO. DESCRIPTION QTY
NOTES:
Part Number 230-4572 Rotor Bolt Kit, includes part numbers 230-6737 and 240-2509
Part Number 250-8228 Caliper Bracket Mounting Bolt Kit, includes P/N 230-6001, 230-6231, 240-1159, 240-2510, 240-8127, 250-8133 & 300-7639
Item 3A is an optional item and is included with the “-”D” kits. Add “-D” to end of part number when ordering
Item 13A is an optional item and is included with the “-”D” kits. Add “-D” to end of part number when ordering
Wilwood offers an optional Braided Stainless Steel Hose Kit. Order part number 220-8176 (not included in kit)
WARNING
INSTALLATION OF THIS KIT SHOULD ONLYBE
PERFORMED BY PERSONS EXPERIENCED IN
THE INSTALLATION AND PROPER OPERATION
OF DISC BRAKE SYSTEMS.
NOTE
SPECIFIC PARTS MAY VARY FROM DIAGRAM
Important Notice - Read This First
Before any tear-down or disassembly begins, review the wheel clearance diagram (Figure 2, page 3) to verify that
there is adequate clearance with the wheels you will be using with this installation.

General Information and Assembly Instructions
•Installation of this kit should only be performed by individuals experienced in the
installation and proper operation of disc brake systems. Prior to any attempt to
install this kit, please check the following to ensure a trouble free installation.
•Inspect the contents of this kit against the parts list to ensure that all
components and hardware are included.
•Make sure this is the correct kit to fit the exact make and model year of
your axle. This kit is designed for direct bolt-on installation to 1997 through
2003 model year Chevrolet C-5 Corvette hubs. 2000-2004 OE C-5, Z06 or
speciality aftermarket wheels. Check wheel clearance diagram.
•Verify your wheel clearance using Figure 2.
•Verify that the factory hub and stud pattern matches the stud hole pattern in the
hats supplied with this kit. Hubs that have been modified with different size
studs or lug patterns may require modifications to the hat that must be
performed by a qualified machinist.
Disassembly
•Disassemble the original equipment front brakes: Raise the front wheels
off the ground and support the front suspension according to the vehicle
manufacturer’s instructions.
•Remove the wheel. Remove the two bolts from the backside of the spindle that
hold the stock caliper mounting bracket and lift off the bracket and stock caliper
as one unit. If space is a problem, you may have to unbolt the stock caliper from the caliper bracket before removal. Save the stock
caliper mounting bracket bolts and washers, they will be utilized during reassembly, then slide off the stock hat and rotor assembly.
•Clean and de-grease the spindles as well as the stock caliper bracket bolts. Remove all nicks or burrs on the spindle snout and threads.
Assembly Instructions (numbers in parenthesis refer to the parts list/diagram on the preceding page):
•The caliper mount bracket assembly (1) should be installed first with clean, dry threads on the mounting bolts. Install the bracket using
the original caliper mount bolts. The bolts will now pass through the spindle from the opposite direction that they were removed (see
Figure 1). The bracket must tighten squarely against the inboard side of the caliper mount bosses on the spindle body. Inspect for
interference from casting irregularities, machining ridges, burrs, etc. Use one thin shim (2) between the bracket and spindle during
initial trial fitting. Later, after the caliper, pad, and rotor alignment has been checked, and any necessary shims have been put in place,
the mount bolts should be coated with red Loctite®271 and torqued to 65 ft-lbs.
•Assemble the rotor (3) to the hat (4) with the bolts (6) and washers (5) provided in the
configuration pictured in Figure 1. Be sure all bolts thread in smoothly and are snug. Then,
torque all bolts in an alternating sequence to 85 in-lbs. The rotor mounting bolts (6) must be
lockwired using standard 0.032 inch diameter stainless steel safety wire as shown in Figure 3.
Please refer to Wilwood’s data sheet DS-386 (available at www.wilwood.org/ds386.pdf) for
complete safety wire installation instructions.
•Install the hat and rotor assembly onto the hub. Check to be sure the hat seats squarely
against the hub. The hub must be free from any rust, debris, casting burrs, machining
irregularities, etc. Use several lug nuts to hold the rotor and hat firmly against the hub during
the next phases of the installation and clearance checking procedures.
•Install spacer (11) and one shim (12) over each stud (10) on the radial mount bracket (1). Slide
the caliper (7) in place over the studs and rotors and install the washer (9) and lock nut (8) to
hold the caliper in place. The caliper bleed screws should be pointing up. Snug the lock nuts
(8) and check that the rotor (3) is centered in the caliper (7). Add or subtract .035" shims (2)
as necessary between the mount bracket and the spindle to center the caliper.
BEGIN BY SLIDING THE 0.032"
DIAMETER WIRE THROUGH TWO OF
THE HOLES (LEFT) THAT ARE 180°
APART. TWIST THE WIRE AS
SHOWN (BELOW) USING SAFETY
WIRE PLIERS. NOW SLIDE ONE
WIRE THROUGH TWO OF THE
HOLES (180° APART) AND WRAP THE
OTHER WIRE AROUND THE BOLT.
TWIST THE WIRES TOGETHER TO
FORM A PIGTAIL. SEE DS-386 FOR
COMPLETE DETAILS.
Figure 3. Safety Wire Diagram
FACE OF
STOCK HUB
INSIDE WHEEL PROFIL
E
(MINIMUM REQUIRED
FOR CLEARANCE)
.30 HAT THICKNESS
REFERENCE
FACE OF WILWOOD HAT
STOCK WHEEL MOUNTING
SURFACE OFFSET
CENTER
LINE OF
WHEEL
1.27 (32,3)
.56 (14,2)
4.86
(123,4)
7.93
(201,4
)
7.83
(198,9)
WHEEL STUDS
WILWOOD
ROTOR
CALIPER
Figure 2. Wheel Clearance Diagram

General Information and Assembly Instructions (Continued)
Assembly Instructions (Continued)
•Remove the caliper center bridge pad retainer bolt, nut, and tube from the caliper. Slide the brake pads (13) into place. They should
install easily without interference. Check that the outside radius of the brake pad is aligned with the outside diameter radius of the rotor
face. Add or subtract shims (12) between the caliper (7) and spacer (11) on the mount bracket (1) to gain the proper alignment.
Reinstall the center bridge pad retainer tube, bolt, and lock nut. The locknut should be snug without play in the bolt or tube. Be
cautious not to over tighten.
•Remove the lug nuts that were holding the hat in place. Install the wheel and torque the lug nuts to specification. Check to see that
the wheel rotates freely without interference.
•Once all clearances have been checked, remove the wheel, caliper, hat, and rotor from the spindle and hub. Secure the caliper
mounting bracket (1) to the spindle using red Loctite®271. Torque the bolts to 65 ft-lbs. Reinstall the hat and rotor assembly
and again use several lug nuts to hold it in place. Reinstall the caliper and torque the caliper nuts (8) to 47 ft-lbs.
Stock Brake Line Disassembly Instructions
•Unbolt banjo bolt from back of caliper.
•Unbolt rubber hose from hard line at frame.
•Pull the clip that holds the rubber hose to the bracket at the frame.
•Install Wilwood’s optional stainless steel braided flexline hose kit, part
number 220-8176 (NOT included in kit), see Figure 4. NOTE: The caliper
inlet hole has a 1/8-27 NPT thread. A steel 90° elbow fitting should be
installed in the caliper. Verify that there is enough length to allow the
wheels to turn lock to lock without straining or pinching the brake line.
THE ORIGINAL EQUIPMENT PRODUCTION RUBBER BRAKE HOSES
WILL NOT ADAPT TO WILWOOD CALIPERS AND ARE NOT
RECOMMENDED.
•Bleed the brake system, referring to additional information on the last
page as necessary.
•Remove the lug nuts that were holding the hat in place. Install the wheel
and torque the lug nuts to specification.
•Repeat this entire procedure for the other wheel.
FLEXLINE
BRACKET
CLIP
90° ELBOW
FRAME
HARDLINE
WILWOOD
SL6 CALIPER
Figure 4. Brake Line Diagram

DS-459A REV DATE: 03-29-04
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-13
1/2-20
9/16-12
9/16-18
5/8-11
5/8-18
85 in-lb
103 in-lb
180 in-lb
198 in-lb
22 ft-lb
30 ft-lb
42 ft-lb
47 ft-lb
65 ft-lb
77 ft-lb
95 ft-lb
105 ft-lb
110 ft-lb
120 ft-lb
Bolt Torque Specifications
BOLT SIZE TORQUE
NOTE: This bolt torque specification list is for
use with specific grades of bolts as supplied in
the particular Wilwood kit and is not intended
as a guide for any other application.
260-1874
260-1876
260-2220
290-0632
290-6209
340-1285
340-1287
260-6764
260-6765
260-6766
260-4893
250-2406
350-2038
270-2016
270-2017
220-0149
220-0842
Wilwood Residual Pressure Valve (2 lb for disc brakes)
Wilwood Residual Pressure Valve (10 lb for drum brakes)
Wilwood Proportioning Valve
Wilwood Racing Brake Fluid (Hi-Temp° 570) (12 oz)
Wilwood Racing Brake Fluid (EXP 600 Plus) (16.9 oz)
Wilwood Floor Mount Brake Pedal (with balance bar)
Wilwood Swing Mount Brake Pedal (with balance bar)
Wilwood 3/4 inch High Volume Aluminum Master Cylinder
Wilwood 7/8 inch High Volume Aluminum Master Cylinder
Wilwood 1 inch High Volume Aluminum Master Cylinder
1-1/16 inch Tandem Master Cylinder (aluminum housing)
Mounting Bracket Kit (tandem master cylinder)
1971 - 1973 Pinto Rack and Pinion (new, not rebuilt)
Quick Release Steering Hub (3/4 inch shaft)
Quick Release Steering Hub (5/8 inch shaft)
Fitting, Straight (1/8-27 NPT to -4)
Fitting, 90° Elbow (1/8-27 NPT to -4)
(Consult the Wilwood Catalog for a complete parts list)
Associated Components
Additional Information and Recommendations
PART NO. DESCRIPTION
Wilwood Disc Brakes • 4700 Calle Bolero, Camarillo, CA 93012 Phone 805 / 388-1188 • Fax 805 / 388-4938
•Fill and bleed the new system with Wilwood Hi-Temp° 570 grade fluid or higher. For severe braking or sustained high heat operation,
use Wilwood EXP 600 Plus Racing Brake Fluid. Used fluid must be completely flushed from the system to prevent contamination.
NOTE: Silicone DOT 5 brake fluid is NOT recommended.
•To properly bleed the brake system, begin with the caliper farthest from the master cylinder. Bleed the outboard bleed screw first, then
the inboard. Repeat the procedure until all calipers in the system are bled, ending with the caliper closest to the master cylinder.
NOTE: When using a new master cylinder, it is important to bench bleed the master cylinder first.
•Test the brake pedal. It should be firm, not spongy and stop at least 1 inch from the floor under heavy load.
If the brake pedal is spongy, bleed the system again.
If the brake pedal is initially firm, but then sinks to the floor, check the system for fluid leaks. Correct the leaks (if applicable) and
then bleed the system again.
If the brake pedal goes to the floor and continued bleeding of the system does not correct the problem, a master cylinder with
increased capacity (larger bore diameter) may be required. Wilwood offers various lightweight master cylinders with large fluid
displacement capacities.
•NOTE: With the installation of after market disc brakes, the wheel track may change depending on the application. Check your wheel
offset before final assembly.
•If after following the instructions, you still have difficulty in assembling or bleeding your Wilwood disc brakes, consult your local chassis
builder, or retailer where the kit was purchased for further assistance.
PAD BEDDING PROCEDURE:
•Pump brakes at low speed to assure proper operation. On the race track, or other safe location, make a series of hard stops until some
brake fade is experienced. Allow brakes to cool while driving at moderate speed to avoid use of the brakes. This process will properly
burnish the brake pads, offering maximum performance.
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