john-h
Well-Known Forum User
To create more posts and add to the tech forum I've written the following tech. note on how to fit the Pug Hilux brake conversion. I've assumed an amount of knowledge and a copy of the Haynes manual. If anyone can improve it or add anything feel free.
Pug Hilux Brake upgrade for S30
You will need
How to do it
Pug Hilux Brake upgrade for S30
You will need
- Vented brake discs for a Peugeot 505 gti or Talbot tagora.
- Brake callipers from a Toyota Hilux 4x4 of Hilux Surf
- Wheel spacers to suit your wheels (8mm thick for standard iron cross wheels)
- Long wheel studs either from the rear of a zed of Nissan Bluebird.
- Hilux brake pads or pads for Subaru WRC
- Tame machinist.
How to do it
- Remove the calliper and hubs from the front axle. Remove the dust shield. Unbolt the the old discs from the hub by putting a wheel on the bench and putting the hub studs back through the holes in the wheel. This stops the hub turning. Then with a long socket handle, undo the disc bolts.
- Drive the disc from the hub with a chisel or wedge (it will be tight on the hub due to corrosion).
- Remove the studs from the hub by fitting an old wheel nut and hitting it with a large hammer.
- The discs can now be machined to fit the hubs. The holes for the studs in the Peugeot disc are on the wrong pitch circle diameter (PCD) and the centre bore is too small to fit on the datsun hub. The machinist needs to open up the bore to be a good fit on the hub (this is not an interference fit but a good sliding fit). 4 new clearance holes need to be drilled between the ones in the Peugeot disc to suit the PCD the zed hub. Machining the bore and marking the new PCD need to be done in a 4 jaw chuck or CNC machining centre to ensure concentricity.
- Rebolt the new discs to the hub.
- Refit the hub.
- Fit the new calliper to the existing bolt holes for the zed calliper.
- Use the existing zed steel pipe work to connect to the calliper.
- Fit the pads (you need to get them the right way up because they are handed)
- Bleed it and all should be well.