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Old 08-13-2016, 01:35 PM   #6
scottyb
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Join Date: Dec 2007
Location: Southern California
Posts: 73,358
Default Re: Ausco cable disc brake install thread

Install the caliper bracket on the axle tube flange where the backing plate was mounted using the same 4 bolts (1/2" socket and wrench) you removed. If the nuts need replacing Please use hardened bolts not fence bolts. Not inferior, left over Chinese hardware. Bolt failure could be serious. Tighten these bolts up good. Note OEM bolts have self locking nuts. Many types of self locking nuts are available, I prefer the stamped or slightly squished type for this application.

Once the flange is mounted, apply a light coat of never-cease to the axle splines and install the HD hub. Torque the nut to 100 pounds (min.) or more as needed to line up with the cotter pin hole. NEVER back the nut off to line up the cotter pin hole. Always go a little tighter, which is why the spec is 90-140 ft. pounds.

Slide the rotor / hub over the lug bolt studs and loosely secure with 1 or 2 lug nuts. Hand tight is all that is needed.

Next place the caliper assembly over the mounting bracket as shown in your directions. If actual install I encourage you to following the instructions. It has great pics for dummies, like us.

Pay attention to the spacers you removed to separate the caliper mounting bracket. There are 2 long and 2 short tubular spaces for each side of the cart. Place a long spacer over the 2 bolts as shown below insert these through the RED brake pads and mounting bracket. Slide the short tubes on the threaded end of the bolt. NOW- wiggle the bolts and spacer a bit until the sleeves seat and there is about 1/2" of thread showing for the nut.

IF 1/4" of thread is showing a spacer is hung up and not seated in it's hole. IMPORTANT 1/2" of thread should be showing for the 9/16ths lock nut to be put on. Install the nuts and rotate the rotor by hand to insure it moves freely.
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