Mitsubishi Lancer Evolution Brembo Brake Caliper Retrofit For The Nissan 240sx

The Nissan 240SX, known as the Silvia in other markets, is a beloved platform for drifting, time attack, and spirited street driving. One of the most common performance upgrades enthusiasts pursue is improving the braking system. While aftermarket brake kits are available, a cost-effective and highly regarded option is retrofitting Brembo brake calipers from the Mitsubishi Lancer Evolution. This article provides a comprehensive guide to this popular modification, covering the benefits, required components, installation process, and considerations for a successful conversion.

Why Evo Brembos on a 240SX?

The Mitsubishi Lancer Evolution (often shortened to "Evo") is a performance icon known for its powerful engine and impressive handling. Its Brembo braking system, designed for high-performance applications, offers a significant upgrade over the 240SX's factory brakes. Here's why this swap is so popular:

Improved Stopping Power: Brembo calipers, with their larger pistons and more aggressive pad compounds, provide significantly increased braking force, reducing stopping distances and improving overall brake performance.
Enhanced Thermal Capacity: Brembo calipers are designed to dissipate heat more effectively than stock calipers, reducing brake fade during intense use, such as track days or aggressive street driving.
Cost-Effectiveness: Sourcing used Evo Brembo calipers is often more affordable than purchasing a complete aftermarket big brake kit, especially for budget-conscious enthusiasts.
Availability: Evo Brembo calipers are relatively common, making them easier to find and source than some other performance brake upgrades.
Aesthetic Appeal: Let's be honest, the Brembo calipers offer a more aggressive and sporty look compared to the 240SX's factory brakes.

Required Components for the Brembo Swap

To successfully install Evo Brembo calipers on your 240SX, you'll need the following components:

Brembo Calipers: Front Brembo calipers from a Lancer Evolution VIII or IX are the most commonly used. Ensure they are in good working condition and free of damage.
Brake Rotors: You'll need rotors that are the correct size and bolt pattern for your 240SX hubs and compatible with the Brembo calipers. Common choices include Z32 (300ZX) rotors or aftermarket rotors specifically designed for this swap.
Caliper Brackets/Adapters: These brackets are essential for mounting the Brembo calipers to the 240SX's spindle. Several aftermarket companies offer brackets specifically designed for this conversion. Choose high-quality brackets from reputable sources to ensure proper fitment and safety.
Brake Pads: Select brake pads suitable for your intended use. Consider performance street pads for daily driving and track-oriented pads for more aggressive applications.
Brake Lines: Stainless steel braided brake lines are highly recommended for improved brake feel and reduced brake line expansion under pressure. They are generally considered a mandatory upgrade for this swap.
Brake Fluid: Use a high-quality DOT 4 brake fluid with a high boiling point to ensure consistent brake performance, especially during demanding driving conditions.
Wheel Spacers (Potentially): Depending on your wheel offset, you may need wheel spacers to clear the larger Brembo calipers. Test fitment is crucial before finalizing your setup.
Hardware: Ensure you have all necessary bolts, washers, and clips for mounting the calipers, rotors, and brake lines. It's often best to purchase a dedicated hardware kit for this swap.

Sourcing the Calipers

You can find Evo Brembo calipers from various sources:

Used Parts Market: Online marketplaces like eBay, forums dedicated to Evo and 240SX owners, and local junkyards are common places to find used calipers. Thoroughly inspect used calipers for damage, corrosion, or signs of leakage before purchasing.
Remanufactured Calipers: Remanufactured calipers have been rebuilt with new seals and components, offering a more reliable option than used calipers.
New Calipers: While the most expensive option, purchasing new Brembo calipers ensures you receive a flawless product with no previous wear and tear.

Installation Process: A Step-by-Step Guide

Disclaimer: Brake work should only be performed by qualified individuals with experience in automotive repair. Improper installation can lead to brake failure and serious injury or death. If you are not comfortable performing this modification yourself, seek professional assistance.

Preparation: Gather all necessary tools and components. Park the 240SX on a level surface, engage the parking brake, and chock the rear wheels for safety.
Remove Existing Brakes: Loosen the lug nuts on the front wheels. Jack up the front of the car and secure it with jack stands. Remove the wheels. Disconnect the brake lines from the factory calipers. Remove the factory calipers and rotors.
Install Caliper Brackets: Install the adapter brackets to the 240SX's spindle according to the manufacturer's instructions. Ensure the brackets are properly aligned and securely fastened. Use new hardware and torque to the specified values.
Install Rotors: Install the Z32 or aftermarket rotors onto the hubs. Secure them with lug nuts or rotor screws.
Mount Brembo Calipers: Mount the Brembo calipers to the adapter brackets. Ensure the calipers are properly aligned with the rotors. Use new hardware and torque to the specified values.
Install Brake Lines: Connect the stainless steel braided brake lines to the Brembo calipers and the 240SX's brake lines. Ensure the connections are tight and leak-free. Use new crush washers if necessary.
Bleed the Brakes: Bleed the entire brake system to remove any air bubbles. Start with the caliper furthest from the master cylinder and work your way closer. Use a high-quality DOT 4 brake fluid.
Install Wheels: Install the wheels and torque the lug nuts to the specified value.
Test Drive: Lower the car and perform a test drive in a safe area. Gradually increase your speed and brake force to ensure the brakes are functioning properly. Listen for any unusual noises or vibrations.
Re-Bleed (If Necessary): If the brake pedal feels spongy or soft, re-bleed the brakes to remove any remaining air bubbles.
Bedding In: Follow the brake pad manufacturer's instructions for bedding in the new brake pads. This process involves a series of controlled braking maneuvers to properly transfer pad material to the rotors.

Important Considerations During Installation

Brake Line Routing: Pay close attention to the routing of the brake lines to ensure they do not rub against any suspension components or the body of the car.
Torque Specifications: Always use a torque wrench and tighten all bolts to the specified torque values. Over-tightening or under-tightening bolts can lead to component failure.
Wheel Clearance: Verify that the Brembo calipers clear your wheels. If necessary, use wheel spacers to achieve proper clearance.
Brake Master Cylinder: While not always required, some users opt to upgrade the brake master cylinder to a larger unit to improve brake pedal feel and performance. This is especially relevant for aggressive track use.

Troubleshooting Common Issues

While the Evo Brembo swap is a relatively straightforward modification, some common issues can arise:

Brake Pedal Sponginess: This is usually caused by air in the brake lines. Re-bleed the brakes thoroughly.
Brake Rubbing: This can be caused by improperly installed calipers, warped rotors, or incorrect brake pad installation. Inspect all components and ensure they are properly aligned.
Vibrations During Braking: This is often caused by warped rotors or uneven brake pad wear. Replace the rotors or brake pads as necessary.
ABS Issues: In rare cases, the Brembo swap can interfere with the ABS system. This may require adjusting the ABS system parameters or installing an aftermarket ABS controller.

Conclusion

The Mitsubishi Lancer Evolution Brembo brake caliper retrofit is a popular and effective upgrade for the Nissan 240SX. By following this guide and paying close attention to detail, you can significantly improve your 240SX's braking performance and enhance your driving experience. Remember to prioritize safety and seek professional assistance if you are not comfortable performing this modification yourself. With careful planning and execution, the Evo Brembo swap can transform your 240SX into a formidable machine on the street or track. Always prioritize safety and consult with a qualified professional if you have any doubts or concerns.