Installation And Performance Review Of A Wilwood Big Brake Kit On A 240sx

So, you're thinking about upgrading the brakes on your 240SX? Good call! The stock brakes, while adequate when new, can definitely become a weak point, especially if you're hitting the track or have added any extra horsepower. A Wilwood big brake kit is a popular and effective solution. I recently installed one on a customer's 240 and thought I'd share my experiences, from installation to real-world performance, to help you decide if it's the right choice for you.

Why Consider a Wilwood Big Brake Kit?

Before diving into the installation, let's talk about the benefits. A big brake kit primarily offers:

Improved Stopping Power: Larger rotors and multi-piston calipers provide a greater clamping force and surface area, resulting in shorter stopping distances.
Better Heat Dissipation: Bigger rotors have more thermal mass, meaning they can absorb more heat before brake fade becomes an issue, crucial for track days or spirited driving.
Enhanced Pedal Feel: The improved hydraulic advantage from the larger calipers often translates to a firmer, more responsive pedal feel.
Aesthetic Upgrade: Let's be honest, they look fantastic behind those wheels!

However, it's not a one-size-fits-all solution. Consider your driving style and needs. If you're just daily driving and rarely push the car hard, the upgrade might be overkill. But for those craving more performance, it's definitely worth exploring.

Choosing the Right Wilwood Kit for Your 240SX

Wilwood offers various kits for the 240SX, typically differentiated by rotor size, caliper type (e.g., Dynalite, Forged Superlite), and whether it's a front or rear kit (or both!). Do your research! Consider these factors:

Wheel Size: Bigger rotors require larger wheels. Check the kit specifications to ensure compatibility with your current (or planned) wheel setup. Don't forget to check wheel offset as well.
Intended Use: A basic kit might suffice for street and occasional track use, while a more aggressive kit with larger rotors and calipers is better suited for dedicated track cars.
Budget: Prices vary significantly between kits. Determine your budget and stick to it. Remember to factor in the cost of brake lines and fluid.

For this installation, we opted for the Wilwood Forged Superlite 6R Big Brake Front Hub Kit, a good balance of performance and value for track days and spirited street driving.

The Installation Process: A Step-by-Step Overview

The installation, while not overly complicated, requires mechanical aptitude and some specialized tools. If you're not comfortable working on brakes, take it to a professional! Brakes are not something you want to mess around with.

Tools Needed:

Jack and Jack Stands
Wheel Chocks
Socket Set (metric)
Wrench Set (metric)
Torque Wrench
Brake Line Wrench (flare nut wrench)
Brake Fluid Catch Bottle
Brake Bleeder Kit (recommended)
Hammer
Punch or Drift
Calipers
Rotors
Brake Pads
New Brake Fluid (DOT 4 recommended)
Anti-Seize Compound
Brake Cleaner
Possibly a Hub Puller depending on how well the old rotors come off.

Step-by-Step Guide:

Safety First: Secure the vehicle on jack stands after chocking the rear wheels. Never work under a vehicle supported only by a jack.
Remove the Wheels: Pretty self-explanatory.
Disconnect the Brake Line: Use a brake line wrench to loosen the brake line fitting at the caliper. Be prepared for brake fluid to leak. Catch it in a bottle. Avoid getting brake fluid on painted surfaces!
Remove the Caliper: Unbolt the old caliper from the spindle.
Remove the Rotor: Depending on how corroded they are, you might need to use a hammer and punch to knock the rotor loose or use a hub puller.
Install the Wilwood Rotor: Mount the new Wilwood rotor onto the hub. Apply a thin layer of anti-seize to the hub surface where the rotor sits.
Install the Caliper Mounting Bracket: Bolt the Wilwood caliper mounting bracket to the spindle. Torque to the specifications provided in the kit instructions! This is crucial.
Install the Caliper: Slide the new Wilwood caliper onto the mounting bracket and secure it with the provided bolts. Again, torque to spec!
Connect the Brake Line: Connect the new brake line to the caliper and the existing hard line on the car. Ensure the connections are tight and leak-free. You might need to use adapters depending on the kit and your existing lines.
Install Brake Pads: Install the brake pads into the caliper, following the kit's instructions.
Repeat on the Other Side: Follow the same steps on the other front wheel.
Bleed the Brakes: This is the most crucial step! Thoroughly bleed the brake system to remove any air. Start with the caliper furthest from the master cylinder. Continue until you have a firm, air-free pedal. A pressure bleeder makes this process much easier.
Install Wheels: Reinstall the wheels and torque the lug nuts to the proper specification.
Test Drive: Perform a test drive in a safe area to ensure the brakes are functioning correctly. Start with gentle stops and gradually increase the braking force. Listen for any unusual noises.

Important Notes:

Follow the Instructions: The Wilwood kit comes with detailed instructions. Read them carefully and follow them precisely.
Torque Everything: Torque all bolts to the specified torque values. Improperly torqued bolts can lead to serious problems.
Bedding In: Properly bed in the brake pads after installation. This involves a series of controlled stops to transfer pad material to the rotor surface. Follow the bedding-in procedure recommended by Wilwood.
Check for Leaks: After the installation and test drive, double-check all brake line connections for leaks.
Brake Fluid: Flush all of the old fluid out of the system. It's cheap insurance and you'll get the full benefits of the new braking system.

Performance Review: Did It Make a Difference?

Absolutely! The difference in braking performance was immediately noticeable. The pedal feel was firmer and more responsive, and the stopping power was significantly improved. On the track, the brakes held up much better to repeated hard braking, with minimal brake fade. The driver reported a noticeable improvement in confidence and control.

Specifically:

Stopping Distances: We didn't perform instrumented testing, but subjectively, stopping distances were noticeably shorter.
Brake Fade: Brake fade was drastically reduced, even after extended track sessions.
Pedal Feel: The pedal feel was much firmer and more linear, providing better feedback to the driver.

Overall, the Wilwood big brake kit significantly improved the braking performance of the 240SX. It's a worthwhile upgrade for anyone looking to enhance their car's stopping power, especially for track use or spirited driving.

Potential Issues and Considerations

While the installation went smoothly, there are a few potential issues to be aware of:

Wheel Clearance: As mentioned earlier, wheel clearance is critical. Ensure your wheels provide adequate clearance for the larger calipers and rotors. You might need to use wheel spacers.
Brake Line Fitment: Occasionally, the supplied brake lines might require slight adjustments or adapters for proper fitment.
Master Cylinder Compatibility: In some cases, upgrading to a larger master cylinder might be necessary to maintain optimal pedal feel and brake bias. It wasn't needed in this case, but it's something to consider, especially with rear brake upgrades as well.
ABS Issues: If your 240SX has ABS, be aware that changing the brake system can sometimes affect ABS performance. Thorough testing is essential.

Cost Breakdown

Here's a rough estimate of the costs involved:

Wilwood Big Brake Kit: $1200 - $2500 (depending on the kit)
Brake Fluid: $30 - $50
Brake Lines (if needed): $100 - $200
Installation (if hiring a professional): $400 - $800 (depending on labor rates)

Total Estimated Cost: $1730 - $3550 (approximately)

Keep in mind that these are just estimates. Prices can vary depending on the specific kit, location, and labor rates.

Conclusion

A Wilwood big brake kit is a significant investment, but it can dramatically improve the braking performance of your 240SX. If you're serious about performance driving or simply want more confidence on the street, it's a worthwhile upgrade. Just be sure to choose the right kit for your needs, follow the installation instructions carefully, and properly bed in the brakes. And as always, when dealing with safety-critical systems like brakes, if you're unsure about anything, consult a qualified mechanic. Happy braking!