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Datsun 240ZFront Brake Upgrade(Replacing Calipers and Rotors) Gary L. Baker, Esq. Patent AttorneyAlthough the front disk brakes of the early 240Zs was considered quite a sporty feature compared to the front drums more common at the time, replacement with more modern calipers and rotors can significantly improve braking in your 240Z.
I've had a variety
of brake problems with my 50-year-old 240Z, such as a broken parking
The stock 240Z calipers use two hydraulic pistons to squeeze the rotor between a pair of essentially square friction pads. The stock rotor is a solid unslotted disk. This design can be improved with additional hydraulic pistons pushing bigger pads onto a slotted rotor. The 4-piston calipers from a 1979-1984Toyota 4x4 happen to have mounting bolt holes arranged to fit perfectly on the 240Z brake caliper mounting brackets. The Toyota friction pads are curved rectangles that extend across the two pistons on each side of the caliper to contact a much larger rotor surface. The four hydraulic pistons provide a larger cross section for a greater multiplication of brake pedal force. I purchased drilled and slotted rotors from Motorsport Auto (1-800-633-6331) to further improve the system (although the Toyota calipers will also fit the stock Datsun rotors). The rotor drilling and slots are said to enhance cooling of the rotor and increase friction by allowing gasses to escape the frictional contact surface between the rotor and pads.
Removal of the stock
calipers and rotor: 1) jack up and redundantly support the Z; 2) remove
the front wheel; 3) disconnect the flexible brake line at the wheel well
mount and plug the line to prevent spillage of brake fluid; 4) remove the
caliper mounting bolts and lift off the caliper; 5) pull off the bearing
hub dust cap, remove the castle nut cotter pin and the castle nut; 6)
The only modification required to install the Toyota calipers is to trim away small sections of the baffle plate to allow clearance for the longer calipers. I used a hand held angle grinder to remove about 1/2 inch of the baffle (you could probably use a hack saw). As I ground, I kept checking the caliper fit and removed the points of contact until the caliper could be installed without interference. A lot of metal filings were produced - keep your bearings out of the area and clean the spindle well before starting reassembly.
Assembly, with the
new caliper and rotor is the opposite of removal steps. Before reassembly,
check the inner and outer bearings and races for scoring; check the rear
bearing seal for damage. Replace any damaged bearing parts.
Pack the bearings and hub with grease. Assembly: 1) pull the rotor
evenly on to the hub (left rotor on left hub, right rotor on right hub)
by progressively and alternately tightening the 4 bolts that fix the hub
to the rotor until the rotor is seated; 2) torque each of
With the upgrade, pedal pressure to stop was less. With hard stops, a little more pressure always gives me more stopping power. BioPatent Communications Contact Me for Discussions About Arts, Technology, and Culture (Blog Me/Pod Me). Return to BioPatent Home Page: Return to BP Home Return to 240Z Home Page: Return to 240Z HomeOther BioPatent Pages: |Protein Purification| |Patent and Trade Secret Page| |Trademark Page| |Patent Services Page| BioPatent 240Z Rejuvenation Page Visited
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