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Location:
Terrigal
Registered:
May 2002
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hilux caliper/pug disc upgrade
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Wed, 16 October 2002 01:47
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hello, i've been collecting all the parts required for the hilux 4 spot caliper upgrade on my ra28.
I organised a rebuild kit for the calipers, which included 8 boots/seals/clips etc all the bits needed. Though they were all 1 size and my calipers have 2 large pistons and 2 smaller pistons. At first I thought the kit was wrong, but since have realised that it seems my pistons are different to the norm. They fit the corona struts (90mm) and appearance wise look the same as other hilux ones.
Any idea what they might be so I can order a correct rebuild kit for them?
Thanks!
Joel
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Location:
NSW
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Wed, 16 October 2002 06:27
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Ummm.... You have got the wrong calipers by the sound of it. They are the ones off the non-ventillated (80-88) Hilux.
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Location:
Terrigal
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Wed, 16 October 2002 07:03
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Ahhh no.. Are they still usable? They do bolt to the strut and the peugot disc seems to fit inside once i machine the inside of the caliper down a bit or the overall diameter of the disc.
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Location:
NSW
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Wed, 16 October 2002 10:19
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Hmmm...interesting. You may have a set of HJ/FJ60 Landcruiser calipers. They had unequal sized pistons, but used ventillated discs.
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Location:
Canberra
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Wed, 16 October 2002 14:27
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yeah mate, they are the landcruiser calipers!
still work fine tho, my mate had a set. but yes those rebuild kits wont work to well hey.
Just one thing, how much were those rebuild kits? i need a kit coz the pistons in mine seeem to stick!! DAMNIT!
and where did u source those kits from? thanx mate!
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Location:
Terrigal
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Wed, 16 October 2002 23:35
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Hey well seeing I got the wrong rebuilt kit maybe we can work something out?
I'll buy a new landcruiser rebuild kit and you can buy mine? I paid $50.
Any idea what model/year landcruiser?
thanks!
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Toymods Social Secretary
Location:
Sydney
Registered:
July 2002
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Re: hilux caliper/pug disc upgrade
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Thu, 17 October 2002 00:48
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out of interest.. how much did this set-up cost you?
Hilux/Landcruiser calipers
Pug discs
Any accessories or other stuff i need
Corona Struts
What have all your guys paid for this set-up?
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Location:
Sydney
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Thu, 17 October 2002 00:59
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well I got my struts for $80 calipers $150 and the disks I'm getting are the DBA peugot rotors slotted and vented $280.
these are the same disks that a group of toymods members had made up in bulk.
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Location:
Sydney
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Thu, 17 October 2002 00:59
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and then a good set of pads ofcourse and the cost of rebuilding the calipers $50.
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Toymods Social Secretary
Location:
Sydney
Registered:
July 2002
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Re: hilux caliper/pug disc upgrade
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Thu, 17 October 2002 01:24
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OOOHOOOOHOOOHH!!!! i might get me a set when we go down to the DBA factory again.... ill be mentioning this on monday.
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Location:
Sydney
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Thu, 17 October 2002 01:27
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I got/getting my set made up through stamry brake and clutch as they did the group buy, and also did the few mods to the rotors neccasary.. a few mm shaved off the outside and the re drilling to suit the hubs
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Location:
Canberra
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Thu, 17 October 2002 01:47
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TurboRA28 :
Yeah thats not a bad idea. But by the time they are packaged and sent here (ACT) it might be cheaper, me buying a new set from some where around here. Unless your price is hell cheap 
Also are yours genuine toyota replacements? or someone else's?
Im after the Toyota ones as i hear they work better.
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Location:
Canberra
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Thu, 17 October 2002 01:51
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Oh yeah, and the calipers that i saw like yours came from a very old Troopy style landcruiser. Dont know the model sorry! i spose most of them would be the same. it was one of those crusty old beige coloured things.
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Location:
adelaide
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Thu, 17 October 2002 02:33
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Hey guys, this just off the topic a little but i am considering doing this front disc upgrade in the not too far off future, but i already have good springs and shockers (kings and KYBs) on the ra28. What i need to know is if there is any way of applying the hilux caliper/vent. disc's to the ra28 strut's..... OR.... if the suspension setup currently in place(cost me lot$$) can be put straight back in combined with corona struts, if they were whats def. needed? Thanks heaps if anyones been in the same situation or has any comments... I just dont want to throw a whole heap of money down the drain when i need new struts for the brake upgrade, cos it took me a while to save for the king springs+kybs and they are good, and i want to keep them if the engine swap goes ahead..
I sent an email to DBA to see if they make or can make any larger ventilated discs for the ra28 that bolt straight on to the strut, but im doubtful and id expect to pay a fair bit if they were custom. And id still need some big calipers. :/ hmm
Anywho thanks again, and turboRA28 i checked out your website Good Work i love how the cars progressed, rally blue paint is sweet! one more thing i wish i could afford 
Take it easy
_______________
BlackRA28
|=SLEEK77=|
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Location:
Brisbane
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Thu, 17 October 2002 02:57
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If you want to keep your existing struts, you should consider the MA61 brake upgrade. These are 258mm vented discs with a big single-piston caliper, and they do an excellent job of pulling up my RA23. The Supra hubs bolt right on to the RA23 spindles, the bearings are exactly the same size.
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Location:
Sydney
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Thu, 17 October 2002 03:12
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the main reason for swapping to the corona struts is it gives you a 90mm bolt holes for your caliper so that way no fabrication is need, besides a 1-2mm washer to space the caliper correctly so that the disc spins in the middle of the caliper.
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Location:
Newcastle
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Thu, 17 October 2002 03:26
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hey mate,
Did the same thing with my ra28.....
the springs and strut interts fit straight into the corona strut no probs.....
so you can have good brakes and keep your nice suspension....
Cheers
Stew
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Location:
A.C.T
Registered:
July 2002
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Re: hilux caliper/pug disc upgrade
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Thu, 17 October 2002 05:23
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Sorry to just barge in like this and ask questions that i'm sure have been answered previously, but i'm a bit lazy to go looking. All i want to know is just the exact parts required, part numbers as well, that i need to do this famous brake upgrade 4 the TA22. If anyone can tell me exactly what model hilux/cruiser calipers and exactly what pug disks, i would be very grateful. If not then i guess i'll have to go searching the forum! Thanx
André
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Toymods Social Secretary
Location:
Sydney
Registered:
July 2002
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Re: hilux caliper/pug disc upgrade
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Thu, 17 October 2002 06:11
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check out the toymods article section... its listed in there
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I supported Toymods
Location:
NE Melbourne
Registered:
May 2002
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Re: hilux caliper/pug disc upgrade
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Thu, 17 October 2002 08:28
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sorry to harass your thread Joel, but everyone keeps asking...
here's an artice that i worte a little while ago, actually for the benefit of one of the many people who send me emails asking about my upgrade. sorry if you have already read this, but i though it might be of benefit to some (like me) who think the article in the Tech Section is a bit brief!!!
(by the way, i encourage this to be posted as an article in the tech section if that's alright too - Nark, is that your area???)
To begin with, the brake upgrade I have on my celica is the regular "Hilux/pug/corona" setup. I followed the details that are described, although not very thoroughly, in the articles section on Toymods, and then worked out the rest myself. I hope my experience can help out others.
Now the common complaint about this setup is that it "will not fit on a TA22." Well I tell you now it does, and it is all nut and bolt stuff!! It is true that the corona struts are of incorrect dimensions to properly run in the TA22, but it is not a difficult task to have the strut appropriately modified.
So the struts are corona XT130 struts. I got these complete with brakes and suspension, just to ensure that I had all the necessary parts if I found myself in trouble! However, really the only parts you need of them is the strut itself (with or without the "wet leg" insert) and the hubs complete with bearings. The calipers are LN106 Hilux calipers. The important thing to note when you obtain these parts is to just quickly measure the distance between the mounting points on the caliper and the strut and just ensure that they match up at 90mm.
The discs are probably the most difficult part of the conversion itself. Although he discs are "off the shelf" pug 604 items, they are not a direct fit for this conversion. Some simple machining is necessary to ensure a proper fit.
With the caliper fitted to the strut, if you measure the effective diameter of the pads, you'll find that they only cover a diameter of 266mm, although the pug 604 discs are 273mm in diameter. So for one, if the pug discs are not turned down they will not fit or look right. Some say that it's easy to just file out the inside of the calipers to accommodate the extra diameter of the discs, I say that's dodgy and the discs should be turned down to 266mm (most specialist brake shops can organise this for you). Besides, what's the point of having a fat band of unused disc spinning outside the pads??? Would look awful if you ask me!!!
Other modifications to the discs are obviously the mounting bolt holes. Again, there are some options here. As the diameter of the existing hole circle is slightly too small they can either be enlarged by drilling out, or a more appropriate solution is to have the holes slotted to make the diameter right. Here, use the hub, or the old corona disc as a guide to the location of the holes. Another solution is to redrill all four holes in other locations…
The caliper can be mounted to the struts such that the caliper is mounted at the back of the strut. There is sufficient room, albeit not a lot, between the caliper and the steering arm and tie rod end. I did not investigate the idea of reversing the struts so I could mount the calipers at the front, I guess I should just leave it how it was supposed to be just like a TA22, XT130 and even the LN106 with the caliper towards the rear!!! Be very careful to decide on your left and right side caliper. Make sure that whichever caliper you choose, that in it's operating location and position, that the bleeder nipple is at the TOP, not the bottom. This is to ensure that when you bleed that brakes, you actually get the air out!!!
When it comes time to do final assembly, I recommend that the calipers are rebuilt with new kits. If you choose to do this then be aware that these calipers have an internal fluid crossover. Most caliper rebuild kits will not come with the seals to rebuild the calipers if you split them in half. I suggest that there is no need to replace the seals on the internal crossover, only the seals and boots on the pistons themselves.
Once you have the discs modified accordingly, it's ready to bolt it up. With the discs bolted to the hubs using the existing bolts fit the hub to the stub (including or excluding the backing plate - I excluded mine) tension the wheel bearings and forget about it. Now if the caliper is bolted directly to the strut now, it will not fit! But don't stress cos all that is needed is some shims to space the caliper back just enough so that the disc spins directly in the centre of the caliper, from memory it's only like 1mm. It seems as if there is not enough room in the caliper to fit the disc, but rest assured it fits!!! The Hilux shares the same thickness (20mm) disc as the pug 604 so there is no reason for this not to fit. About now you'll also find that the caliper bolts used to hold the corona calipers to the corona strut are too short. You can either get new bolts, or as I did, found that the struts I got came with a set of bolts used the bolt the bottom of the strut to the steering arm. These bolts are the correct thread, but slightly longer and are just perfect for this job!!
There is now another slight problem. You'll notice that the Hilux calipers will not accept the brake line that you're likely to remove from the TA22 caliper, the Hilux caliper instead uses a flange type arrangement. My solution to this was to have some short lengths of brake pipe made up at the brake shop for a few bucks with new fittings that bolt into the back of the caliper. From here the brake pipe is bent to where it meets up with the flexible brake hose at the back of the strut where the clip holds it rigidly in place. There is another advantage to this. Having a shorter length of flexible brake hose means less balooning and better braking feel!!!
The new calipers have over 4 times the size when it comes to piston size, so as you can imagine there is a great loss in pedal when these calipers are fitted. I found that it took almost half the travel of the ped before the brakes take up and begin braking. This is because the master cylinder size is far too small. I looked into replacement master cylinders but found that the cheapest and easiest solution was to have the existing mastercylinder modified. For around $200 I had my old TA22 master cylinder bored out for 13/16 inch to 15/16 inch with new piston and seal. So effectively I got a brand new master cylinder that was suited to the job that bolted right in without modifications to any brake lines. This I strongly recommend as part of the brake canversion!
Back to the struts themselves. As you probably already know, these struts are too long for a TA22, but only by approx 25mm. If you are like me and want to put them in as a temp fix, then you could quite easily get away with it. Apart from being the wrong total length, the lower spring clamp is also located differently to the TA22 strut. I fact this too sits 25mm higher up the strut than the TA22 one, meaning the if it is not relocated, a spring of 25mm shorter length will be required for the correct ride height.
Having fitted the corona strut into my TA22 unmodified, I think that the camber is also not right… I have not got around to having it checked out, but when I do, part of the modifications that I will be making to the struts will be to have them bent to my desired camber, as well as having them shortened. I think I will go to about 1 - 1.5 deg neg camber for nice handling!!! I will have the struts shortened so that their specs will be back to those of a TA22 so that getting hold of springs and shocks will be easy. I was toying with the idea of height adjustable coil overs, but I really don't think it's worth the cost!! Although I do think it is worth swapping over to the TA22 lower spring clamp off the TA22 spring. And when mounted the same distance from the stub axle, there is no reason that correct spec TA22 springs can't be used!!!
One onther tiny aspect is brake pads. I was lucky enough to have my caliper arrive with almost new brake pads fitted already. So for initial setup it was great to have the pads there ready to go. But even with the HUGE increase in braking performance, I was still able to achieve brake fade. This was not brake fade caused by excessive heat reaching the fluid and boiling it, but rather I was able to over heat the pads at about their maximum 450 degC rating. I knew I had to have better so I have now got a set of EBC Green Stuff pads from a Mitsubishi GTO, rated to 650 degC. These pads fit right in. the outer pads are no drama, but the inner pads did require some minor surgery on the bench grinderso that they would clear the caliper mounts, but not difficult to do.
So I now have huge brakes, fitting behind my wheels, a pedal that feels like stock and the capability to beat some quite exotic cars under brakes. Since the new pads I have not been able to reach the limits of my brakes, and with the stock rear drums still in use, I couldn't be happier with the performance. The cost all up with the performance pads, master cylinder everything was about $1100. this is not a really good guide as all parts and work was done at trade prices.
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