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1. The new rotors come with the bearing races pressed in, so its a good idea to pick up some new bearings. Start by packing the new bearings with high-temp disc brake grease. The procedure is to put a glob of grease in your palm and scrape the bearing across, forcing grease between the rollers. 2. The greased inner bearing is set in the rotor and a new seal is tapped into place. The outer bearing will be installed when the rotor is on the spindle. 3. Begin disassembly of the old brakes by removing the two caliper pivot bolts. Unless you plan to replace the calipers, do not detach the brake line. However you may want to replace the rubber line at this point, especially if it is cracked. Old rubber lines flex, resulting in a mushy brake pedal.
4. Support the caliper so that is does not hang from the brake hose. We used a small bungy cord and hung the caliper from one of the holes in the shock tower. 5 Remove the dust cap, cotter pin, and nut from the rotor. 6. Slide the rotor off the spindle.
7. Clean off any old grease from the spindle and inspect it for grooves, nicks, or rust. If it is damaged you should consider replacing the spindle as it will lead to accelerated bearing wear. 8. A trick to increase cooling of the front brakes is to trim the dust shield as shown here. You'll need to remove the shield from the spindle (three screws) and trim it around the mounting holes using tin-snips. You cannot leave the dust shield off entirely because the cupped portion keeps dirt out of the inner bearing. 9. Coat the spindle with new grease and slide the new rotor on carefully. Pack the outer bearing with grease and slide it into the rotor.
10. Replace the retaining washer and nut and adjust the bearings. The proper procedure is to turn the rotor while tightening the nut to approximately 20 lb.ft. Then back the nut 1/4 turn and line up the cotter sleeve and pin. The rotor should not have any play in it, but should not bind when you try to spin it. (Expect it to spin about 1 revolution before coming to a stop.)
11. Before installing the new pads, use a large C-clamp to push the piston into its bore, otherwise you'll have a tough time getting the caliper over the rotor. 12. Set the new pads into the calipers. We used the metallic pads from GTRotors, however any semi or full metallic pad will perform well with rotors. (See brake pad basics.) We did not use any anti-squeal compound ("blue-goo"), but you can if you feel your calipers are prone to squeaking.
13. Clean the rotor with brake cleaner to remove and grease and oil from your hands, then slip the loaded caliper over the rotor and install the pivot bolts. Use a light coating of white lithium grease on the pin, and a small dab of RTV silicone or Loctite on the threads. 14. The finished front brakes look great. We'll bleed them after the rear drums are completed. 15. With the car supported on jack stands and front wheels chocked, slide the drums off the rear axle. (The parking brake must be released.)
16. The best way to work on drum brakes, with all the complex springs, is to work on one side at a time, using the other side as a reference. A shop manual is also a good idea. 17. Start disassembly be removing the side springs which secure the shoes to the backing plate. Note the special brake tool we are using -it is cheap (under $10) and will save you a lot of aggravation so pick one up. 18. Then remove the two springs shown be prying them off the mounting pin with a large screwdriver.
The shoes can then be removed from the backing plate.
19. Use brake cleaner to thoroughly clean the backing plate. Drum brakes collect a lot of brake dust, be sure to clean it all out. 20. Since we were replacing the wheel cylinders, we disconnected the rear brake lines. Be careful not to round off the fitting -use a flare wrench or vise grips. 21. Our wheel cylinder was in bad shape. The cylinders get packed with brake dust which causes them to leak, and bind.
22. Install the new wheel cylinder and shoes. Be sure to reattach the springs in the correct order. Use the repair manual and the other side as a reference. 23. Adjust the parking brake adjuster so that the drum just barely slips over the shoes without using any force.

24. Clean the machined drum surface with brake cleaner to remove any grease before placing the drum over the shoes.
Bleeding the brakes
Start by filling the reservoir with quality brake fluid, we recommend DOT 4 or DOT 5.1. See below for more on brake fluids.

Bleeding the brakes is a snap with the Speed Bleeder screws. Attach a clear silicone hose (available from SpeedBleeder) to the screw and a jar to collect the fluid. Starting with the wheel furthest from the master cylinder, in most cases this is the passenger-side rear. Then do the drivers rear, pass. front, and finally the drivers front caliper. Simply loosen the bleed screw one turn, and slowly pump the brake pedal to the floor ten to fifteen times, or until you see clear fluid flowing without any air bubbles. There is no need to have someone close the screw while the pedal is depressed. The valve in the screw prevents siphoning, so you can walk back and tighten the screw yourself!

Always ensure the reservoir has fluid, if it goes empty you'll pump air into the lines and have to start all over!

Breaking in the brakes
New brake pads need to be "bedded", a process which cooks off the binder resins in the pad by deliberately over heating the pad. If you don't do this, the first time you decide to panic stop the brakes will fade big time and you'll probably hit whatever you were trying to avoid.

Drive at about 50-60 mph (on a safe. open, road) and apply the brakes, dragging them while giving the car gas to maintain the speed. Drag the brakes for about 10 seconds and release. Drive for about one minute off the brakes to let them cool, then drag the brakes again for thirty seconds. The brakes may begin to smoke, chatter, and stink and you might feel a some fade, this is normal. Repeat this up to three times, then let the brakes cool for several minutes. Finally, make some hard stops from 40, then 50, then 60 mph, allowing the brakes to cool a couple minutes between each stop. You should feel the brakes progressively feel better and stop faster. Be sure to check the reservoir and bleeder screws to ensure there is no leaking of brake fluid.

Brake Fluid Basics
Two types of brake fluid are commonly used in the automotive world. The most common type uses a Poly Glycol Ether, the other uses a Silicone or Silicium-based Polymer. Both Fluids are common but perform and feel different. Fluids containing Polyalklene Glycol Ether are more widely used and are the only fluids that should be used in racing brake systems. Silicone based fluids are used where introduction of water into the braking system if of high concern, such as with military vehicles. Silicone based fluids are non-hydroscopic meaning that they will not absorb or mix with water, however silicone fluids compress more than poly glycol ether types, which leads to poor, "spongy" pedal feel. We don't recommend silicone fluids, unless you have a show car -silicone fluids don't eat up paint.

Poly glycol ether fluids are hydroscopic meaning they have an ability to mix with water and still perform adequately. However, water will drastically reduce the boiling point of fluid which can lead to fluid fade. In fact they are so hydroscopic that they fluid will pull moisture out of the air, which is why it is imperative to use fresh brake fluid and never keep the master cylinder cover open for a long period of time. These fluids are not easily compressible and give much better feel over silicone types.

Water eventually enters the brake system in several ways. As calipers, wheel cylinders, and brake lines heat up and then cool repeatedly, condensation builds up in the system. Diffusion is another way in that moisture may enter the system. Diffusion occurs when over time moisture in the atmosphere enters through rubber brake hoses. The use of hoses made from EPDM materials (Ethlene-Propylene-Diene-Materials), or steel braided lines with Teflon sleeves will reduce the amount of diffusion.

All brake fluids must meet Department of Transportation (DOT) minimal specifications for brake fluid. Keep in mind these are minimal standards, and usually manufacturers exceed these standards. All "race" fluids exceed these standards. A DOT 3 or 4 fluid is really all you need for street performance driving. Currently their are three standards based on boiling points and fluid type. DOT 3, DOT 4 are for Poly glycol ether based fluids, DOT 5.1 is for fluids based with Polyalkylene Glycol Ether) and DOT 5 is for Silicone based fluids.

DRY BOILING POINT: The temperatures that brake fluid will boil with no water present in the system.
WET BOILING POINT: The minimum temperatures that brake fluids will begin to boil when the brake system contains 3% water by volume of the system.

The following chart shows the boiling points:

Fluid Spec. Type
Dry Boiling Point
Wet Boiling Point
DOT 3 Poly glycol ether
401ºF
284º F
DOT 4 Poly glycol ether
446º F
311º F
DOT 5 Silicone
500º F
356º F
DOT 5.1 Polyalkylene glycol ether
518º F
375º F

Brake Pad Basics
The GT Rotors and Drums can be used with any pad type, however we've found semi-metallic pads to perform the best for all around street performance.

Organic pads are typically made with cellulose and kevlar, fiberglass or mineral filler material (used to be asbestos). The cellulose is held together with a phenolic resin binder which is a heat resistant thermosetting resin. Organic pads have a good coefficient of friction for a light pedal effort, and work well at low temperatures. They are also quiet and do not wear the rotor or drum as much as metallic pads.. They do not work so good for high performance use as they quickly wear, fade, oxidize and crumble.

Semi-Metallic pads have some powdered metal added to the mix to help stabilize the coefficient of friction at higher temperatures. Typically powdered brass, iron or bronze is added. Chopped brass or bronze wire is sometimes added to help give the pad more mechanical strength. Most stock pads on newer car are semi-metallic. Usually these pads are excellent for all-around use. They can run the gamut from very little metal to almost all metal. The more metal usually means better high temp properties, more noise, more rotor wear and less effective cold braking. Carbon powdered is added to "carbon-metallic" pads to further improve high temperature properties.

Full metallic pads are made of sintered metal with very little binder. Sintered metal is powdered metal that is pressed into a mold at high temperatures until it becomes a more or less homogeneous piece. Pads of this type are pretty aggressive with ones made of brass, bronze or copper or a mix of metals being more streetable and ones using iron being more high temperature oriented. For very high temperature use, ceramic powder is added to the pad material. Full metal pads are noisy, don’t grip when cold or wet and chew up rotors pretty fast.

GROB-TILL INDUSTRIES, INC.
www.gtrotors.com
32 Wembley Drive
Mt. Laurel, NJ 08054
856-722-6707/ fax 856-722-6745
info@gtrotors.com


Speed Bleeder Products
http://www.speedbleeder.com/
P.O.Box 306
Lemont, Illinois 60439 USA
630-739-4620/ fax 630-739-9626
speedbleeder@ameritech.net


 

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