HOPPERS STOPPERS

9 Nevada Crt. Hoppers Crossing, VIC 3029

PH. (03) 97486950 FAX. (03) 9748 5965

FITTING INSTRUCTIONS
300 mm Big Brake Upgrade Kit for Rodeo to 5 stud Commodore pattern

REQUIREMENTS

Minimum 16” wheels, Commodore pattern Your existing master cylinder should be
compatible with this upgrade, however if your vehicle is fitted with a 15/16” bore
master cylinder, and the pedal feels spongy, then changing to a 1” master cylinder
would improve the pedal feel. The standard booster and original rear brakes all in
good condition, will work correctly with this larger front brake kit.

CONTENTS OF KIT

2 off disc rotors 504

2 off calipers type 2 with pads DB1375
2 off mounting hubs, Commodore 5 stud pattern, with Rodeo seals and bearings.
2 off Mounting Plates.48336
4 off M12 bolts, 1.75 pitch by 30 long gr 8.CAPSCREWS
4 off M12 spring washers.
2 off brake hoses to suit.560long, m21 and mf16
2 off banjo bolts and 4 off copper washers.

INSTRUCTIONS

1. Jack car at front of vehicle using the recommended jacking points & place on jack
stands. Remove the front wheels. On each side undo the brake hose at the frame
and remove the old calipers.

2. Remove the grease cap, remove the split pin and undo the wheel bearing retaining
nut. Remove the old disc rotor complete with wheel bearings. Remove the old
backing plate. Clean and inspect stub axle, if damaged it should be replaced.

3. Bolt the 10 mm thick steel caliper mounting plate to the rear of the stub axle with
the original 14 mm x 25 mm long bolts with spring washers and nuts into the
original caliper mounting holes..
4. Grease the new mounting hub and wheel bearing sets and install the inner bearing
before fitting the grease seal into the hub with a suitable drift. Install the hub onto
the stub axle. Install the outer bearing, refit the bearing tab washer and fit the
centre nut, tightening to recommended preload, which for taper roller bearings
should allow a small amount of end float rather than too tight which will destroy
the bearings. Fit the original castle washer and a new split pin. Fit the grease cap.

5. Sit the disc rotor over the hub, ensuring the holes in the rotor are fully on the steps
on the studs and temporarily hold in place with a pair of wheel nuts. (On
completion, the wheel holds the disc firm).

6. Sit the caliper over the disc, ensuring that the BLEEDER IS AT THE TOP AND
THE HOSE COMING IN UNDERNEATH then assemble the caliper carefully
starting the 12 mm x 30 mm capscrews. When all is okay, fully tighten all bolts.
7. Fit the hose to the caliper with one copper washer each side of the Banjo. Bolt the
bracket to the rail and install the horseshoe clip provided ensuring that the hose is
not twisted. Refit the 10 mm pipe fitting and tighten.

8. After installing both sides, bleed the brakes in the normal fashion checking for
leaks and ensuring that a firm pedal feel has been achieved. Reinstall the front
 wheels, checking for caliper clearance and check for hose clearance relative to the
rim and suspension including on full lock and full travel in all directions.

9. Lower car onto ground, again check for pedal feel before carefully road testing,
remember that new pads do not stop perfectly for the first few applications and
that all new brakes require bedding in before working to their best.

Victorian Vehicle Standards Information section 8 and similar standards in each state
advise that an approved Automotive Engineer should inspect any brake alterations,
where they were not an original factory option.
We therefore recommend that the final car be inspected to ensure compliance if
necessary.