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Tutorial: Hilux Caliper/S13 Rotor front conversion for 260Z.

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Lurch:
This article is a step-by-step guide to mounting Hilux 4-spot vented calipers & S13 vented rotors onto the front of your 260Z.
Please rear through this entire article in full BEFORE you attempt the conversion.
It is recommend you also fit a larger Brake M/C before you start – a 280ZX 15/16” one would be suitable.
You should be able to complete this conversion in an afternoon PROVIDING you have the required parts & tools.
It is also recommended that you recondition the calipers prior to use, fit new pads & rotors.
This conversion should also fit under most 14” rims – but check first.
This conversion will also fit a 240Z IF you use 260Z hubs.

Items you’ll need:
1 pair of Hilux/4-Runner 4-spot vented calipers.
Modified S13 vented Disc Rotors – DBA Part No: DBA 919
Brake pads – part No. - TBA.
1mm stainless steel washers, 13mm hole: 28 of.
OR machined 7mm spacer to suit.
The original bolts from your old brakes.
Workshop manual.

Tools:
Angle grinder with 1mm cutting disc.
Bench vice.
Metric spanner set.
Metric socket set.
Tension wrench.
Pliers – multi grips & pointy nose.
Hammer.
Phillips head screwdriver.
Loctite.
HTB grease.
Brake fluid.

PPE:
Goggles or safety glasses
Earplugs or ear muffs.
Gloves.

Before you start:
You have to get the S13 rotors modified to fit the Zed hub.
The centre hole needs to be enlarged to 81mm & new hub mounting holes drilled in a different PCD to suit.
You also need to have 5mm taken off the OD of the rotor, otherwise it fouls the caliper.
I had all this carried out by Rob at Robco Engineering: http://www.viczcar.com/forum/index.php/topic,1861.0.html
See pics - stock rotor on the left.

Lurch:
Step 1:
Jack the Zed up & pace securely on axel stands.
Remove the road wheels.
Undo the the 2, 17mm headed bolts that secure the caliper to the strut.
Wiggle the caliper off the rotor & rest it on the Tie-Rod out of the way – keeping the brake line connected.

Step 2:
Remove the dust cap on the hub.
Remove the split pin & then undo the hub nut.
Withdraw the rotor/hub assembly off the stub axel.

Step 3:
Tighten the hub into the vice with the back of the rotor facing upwards.
Undo the 4, 14mm headed bolts that secure the hub to the rotor.
Tap the hub out of the rotor with a Nylon or Copper mallet – it’ll be fairly tight to get apart.
Once apart, slide the hub back onto the S13 rotor. (Feel free to paint it at this stage).
Refit the hub bolts back into position, but put a dob of Loctite on the thread.
Torque the bolts up to 50ft/lbs.
It is a good idea at this stage to repack the wheel bearings with new HTB grease.

Lurch:
Step 4:
Slide the new hub assembly back onto the stub axel, & refit the hub nut.
Torque the hub nut up to 45ft/lbs THEN UNDO it ¼ of a turn.
Refit the lock ring & split pin. Tap the dust cover back on.

Step 5:
With the original 17mm headed caliper bolts, slide through the caliper & put 7 of the 1mm stainless washers on the other side of each bolt (or the 7mm spacers).
Then bolt the Hilux caliper into place (make sure the bleed nipple it at the top).
I dob of Loctite on the threads is also recommended. Torque to 60ft/lbs.
Refer to pic for clarification.
Undo the brake line on the old calipers & screw into the back of the Hilux calipers.
Fit the new brake pads.
Bleed the calipers starting with the passenger side, then the driver’s side.
Refit the road wheels & lower the car – you’re now DONE!

NOTE: If you wish to fit the backing plates, you will have to trim them back with the angle grinder so they will fit past the Hilux calipers. (I don’t run the backing plates).

Lurch:
Disclaimer:
I, in not way take responsibility for anyone’s actions in performing this conversion.
I suggest you check with the suitable authorities as to the legalities & safety of this conversion.
DO THIS AT YOUR OWN RISK!!!

If this article doesn't make sense or you have any trouble with the conversion PLEASE LET ME KNOW!!!
And no Simon, I'm not going to paint any of it! :D

Price breakdown:
New S13 rotors: $400
Hilux calipers: $200 pair.
Rotor machining: $80
S/Steel washers: $2.00
TOTAL: $682.00  :o
Brake pads: $0-$300. I haven't included pads because of price variances.
I also haven't included the cost of reco'ing the calipers because of price variances.

ZED660:
Lurch,

Just an addition to your good work.  An option to the S13 rotor is a Peugeot 504/505 rotor (RDA part 272S), while it also needs to have the centre hole enlarged from 77mm to 81 and the stud holes redrilled to 114.3 PCD, its diameter is 273mm which is only 2mm larger than the std Z rotor and doesn't need machining the OD and fits perfectly on a 260Z hub with the Hilux/landcruiser caliper. Also the 'height' is 43mm compared to the Z of 43.5. 

Just an alternative! Keep up the good work.

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