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Alcon Advantage Extreme brake kit installation instructions
Important: read these instructions carefully before fitment.
Alcon Advantage Extreme brake kits are designed to replace the original brake calipers and discs. However, vehicle production tolerances may exceed those that the kit will accommodate, and the points below must be carefully observed during installation to ensure that the correct clearances are maintained. This brake kit must be fitted by a suitably qualified mechanic.
- Remove the original caliper and disc
- Raise the vehicle on a suitable lift or stands and remove the wheels.
- Clamp the flexible brake hose to reduce brake fluid loss and disconnect the hose from the caliper. Disconnect any pad wear indicator wires and remove the caliper.
- Remove the brake disc. Fit the new caliper and disc
- Ensure that the hub flange is completely flat and clean. Note that any ‘bruising’ or out of flatness will cause brake vibration.
- If necessary, prepare the hub face to remove any high spots prior to fitting the brake disc.
- Fit the disc assembly to the hub. The discs are handed and must be fitted to the correct side of the vehicle, with direction of rotation as shown right. With the disc assembled to the hub, check that there is a minimum of 5mm clearance between the disc inner face and the lower suspension/steering joint.
- Unless special longer bolts are provided in the kit, use the original bolts and washers to loosely bolt the mounting bracket to the upright. Locate the caliper over the disc and fit the caliper retaining bolts. Do not tighten at this stage. The caliper must be orientated so that the disc rotates past the small piston first, and with bleed screws uppermost.
- To prevent overheating, radial clearance between the disc and caliper must not be less than 2.5mm in all directions. When the pads are fitted, the top edge of the pads should be approximately 0.8mm below the disc outside diameter and the disc must be central in the caliper within +/- 0.5mm. Use the 0.5mm shims provided to lift the caliper on the bracket or to adjust the bracket position until the caliper is correctly positioned. Fit an equal quantity of shims to each end of the bracket as required.
- Fit the road wheel to check there is a minimum of 2.5mm clearance between the wheel and caliper in all directions.
- Do not make any modifications to the caliper. Alcon accepts no liability whatsoever for the consequences of using a caliper that has been modified without its express written approval.
- When the caliper/bracket assembly has been positioned correctly and clearances have been checked, remove and clean the bracket to upright mounting bolts. Apply thread locking compound to the threads, fit the bracket to the upright and tighten the bolts to the vehicle manufacturers’ specified torque.
- Remove the caliper retaining bolts and apply thread locking compound to the threads. Fit each bolts with the washer provided and tighten to 108Nm
- Check that new pads move freely in the caliper. With the pistons pushed back into the bores, there should be a minimum clearance of:
- 0.25mm between the piston end and pad backplate
- 0.4mm between end of the pad and the caliper
- Remove the original hose and replace with the braided hose supplied. Connect the hose to the caliper and, ensuring it is not twisted, connect it to the vehicle, including the original fastening clip. Check that the brake line length allows for all combinations of steering lock and suspension movement and that the hose does not come into contact with any suspension component, the wheel or the tyre in any position.
- Tie-back the pad wear indicator wires.