www.wilwood.

com DS-1022

ASSEMBLY INSTRUCTIONS
FOR
1990 - 2005 MAZDA MIATA*
*For additional vehicle compatibility, visit www.wilwood.com

DYNAPRO 6 FRONT BRAKE KIT

WITH 11.00” DIAMETER VENTED GT ROTOR
BASE PART NUMBER

140-13380
DISC BRAKES SHOULD ONLY BE INSTALLED BY SOMEONE
EXPERIENCED AND COMPETENT IN THE INSTALLATION AND
MAINTENANCE OF DISC BRAKES
READ ALL WARNINGS
WARNING
IT IS THE RESPONSIBILITY OF THE PERSON INSTALLING ANY BRAKE COMPONENT OR KIT TO DETERMINE THE SUITABILITY OF THE
COMPONENT OR KIT FOR THAT PARTICULAR APPLICATION. IF YOU ARE NOT SURE HOW TO SAFELY USE THIS BRAKE COMPONENT OR
KIT, YOU SHOULD NOT INSTALL OR USE IT. DO NOT ASSUME ANYTHING. IMPROPERLY INSTALLED OR MAINTAINED BRAKES ARE
DANGEROUS. IF YOU ARE NOT SURE, GET HELP OR RETURN THE PRODUCT. YOU MAY OBTAIN ADDITIONAL INFORMATION AND
TECHNICAL SUPPORT BY CALLING WILWOOD AT (805) 388-1188, OR VISIT OUR WEB SITE AT WWW.WILWOOD.COM. USE OF WILWOOD
TECHNICAL SUPPORT DOES NOT GUARANTEE PROPER INSTALLATION. YOU, OR THE PERSON WHO DOES THE INSTALLATION MUST
KNOW HOW TO PROPERLY USE THIS PRODUCT. IT IS NOT POSSIBLE OVER THE PHONE TO UNDERSTAND OR FORESEE ALL THE ISSUES
THAT MIGHT ARISE IN YOUR INSTALLATION.

RACING EQUIPMENT AND BRAKES MUST BE MAINTAINED AND SHOULD BE CHECKED REGULARLY FOR FATIGUE, DAMAGE, AND WEAR.

Need Additional Information? Use Your

SmartPhone and Jump to Our Technical
Tips Section on Our Web Site.

WARNING
DO NOT OPERATE ANY VEHICLE ON UNTESTED BRAKES!
SEE MINIMUM TEST PROCEDURE WITHIN
ALWAYS UTILIZE SAFETY RESTRAINT SYSTEMS AND ALL OTHER AVAILABLE SAFETY EQUIPMENT WHILE OPERATING THE VEHICLE

IMPORTANT • READ THE DISCLAIMER OF WARRANTY INCLUDED IN THE KIT

NOTE: Some cleaners may stain or remove the finish on brake system components. Test the cleaner on a hidden portion
of the component before general use.
Important Notice - Read This First

Before any tear-down or disassembly begins, review the following information:

• Review the Wheel Clearance Diagram (Figure 2, page 3) to verify that there is adequate clearance with the
wheels you will be using with the installation.
• This brake kit does not include flex lines. OEM brake lines will not adapt to Wilwood calipers. Check the
assembly instructions, or associated components section for brake line recommendations before assembly.
In addition, Wilwood offers an extensive listing of brake lines and fittings on our web site: www.wilwood.com.
• Due to OEM production differences and other variations from vehicle to vehicle, the fastener hardware and
other components in this kit may not be suitable for a specific application or vehicle.
• It is the responsibility of the purchaser and installer of this kit to verify suitability / fitment of all components
and ensure all fasteners and hardware achieve complete and proper engagement. Improper or inadequate
engagement can lead to component failure.

Photographic Tip
Important and highly recommended: Take photos of brake system before disassembly and during the disassembly process. In the
event, trouble-shooting photos can be life savers. Many vehicles have undocumented variations, photos will make it much simpler for
Wilwood to assist you if you have a problem.

Exploded Assembly Diagram

FRONT OF VEHICLE 2
3

4
1

12

11

13

WARNING
INSTALLATION OF THIS KIT SHOULD
ONLY BE PERFORMED BY PERSONS
6 PIST

EXPERIENCED IN THE INSTALLATION 10

ON

AND PROPER OPERATION OF DISC

BRAKE SYSTEMS.
14
NOTE
SPECIFIC PARTS MAY VARY FROM
DIAGRAM

Figure 1. Typical Installation Configuration

Page 2
 Parts List

ITEM NO. PART NO. DESCRIPTION QTY

1 250-11651 Bracket, Caliper Mounting (pair, one each, left and right) 2
2 230-9664 Bolt, M10-1.5 x 35mm Long, Hex Head 4
3 240-1934 Washer, .406 I.D. x .82 O.D. x .06 Thick 4
4 300-11652 Spacer, .165 Long 4
5 300-11653 Adapter, Rotor Registration 2
6 160-12892 Rotor, .81” Thk x 11.00” Dia, 6 x 6.25” Bolt Circle, Spec 37 2
7 170-11682 Hat, 4 x 3.93, .750 Offset, 6 x 6.25 Bolt Circle 2
8 300-7316 Pad Clip Retainer 2
9 230-11935 Bolt, 5/16-18 x 1.00 Long, Torx Button Head 12
10 120-13438/39-BK Caliper, DynaPro 6, Black 2
10A 120-13438/39-RD Caliper, DynaPro 6, Red 2
11 240-10190 Washer, .391 I.D. x .625 O.D. x .063 Thick 4
12 230-10025 Bolt, 3/8-24 x 1.25 Long, Hex Head 4
13 240-1159 Shim, .035 Thick 16
14 150-10006K Pad, BP-10, Axle Set 1

NOTES:
Part Number 230-11705 Bolt Kit, bracket bolt kit, includes part numbers 230-9664 and 240-1934
Part Number 230-12176 Bolt Kit, hat to rotor, includes part number 230-11935
Part Number 230-11861 Bolt Kit, caliper to bracket, includes part numbers 230-10025, 240-10190 and 240-1159
Item 10A is an optional item and is included in the (R) red caliper kits. Add “-R” to end of part number when ordering.

General Information and Disassembly Instructions

• Installation of this kit should ONLY be performed by persons experienced in the .71 (18,0) .50 (12,7)
installation and proper operation of disc brake systems. Before assembling this RADIUS

Wilwood disc brake kit, double check the following to ensure a trouble free CALIPER
installation.
6.67
(169,4)

• Inspect the contents of this kit against the parts list to ensure that all components
and hardware are included.

• Make sure this is the correct kit to fit the exact make and model year of your 3.64
(92,5)
vehicle. This kit is designed for direct bolt-on installation to 1990 through 2005
model year Mazda Miata axle hubs.

• Verify your wheel clearance using Figure 2. CENTER

LINE OF
WHEEL 2.17 (55,1)
CENTER REGISTRATION
• Verify that the factory axle hub center register diameter and lug pattern match
those in the new hat and registration ring. NOTE: Axle hubs that have been
modified with different size studs or lug patterns may require modifications to the
WHEEL MOUNT SURFACE
new hat that must be performed by a qualified machinist.

Disassembly WILWOOD ROTOR

• Disassemble the original equipment front brakes:
Raise the front wheels off the ground and support the front suspension .81 (20,6) ROTOR THICKNESS

according to the vehicle manufacturer’s instructions. NOTE: A MINIMUM OF .080” CLEARANCE MUST BE MAINTAINED
BETWEEN THE WHEEL AND CALIPER IN ALL AREAS

Remove the front wheels, calipers and rotors. Figure 2. Wheel Clearance Diagram

•Remove any nicks or burrs on the axle hub and upright that may interfere with
the installation of the new brake components.

•Clean and de-grease the axle hub, dust shield, and caliper mounting bosses.

Page 3
 Assembly Instructions
Assembly Instructions (numbers in parenthesis refer to the parts list and Figure 1 on the preceding pages): CAUTION: All mounting
bolts must fully engage clinch nuts. Be sure to check that all bolts are either flush or protruding through flanged side of clinch nut after
shimming, Figure 3.

• Orient the caliper mount bracket (1) as shown in Figure 1 and

Photo 1, and install using bolts (2) and washers (3). Place a
spacer (4) on each bolt between the bracket and caliper
mounting bosses, Figure 1 and Photo 2. Ensure that the flanged
heads of the clinch nuts in the bracket are facing outboard,
Photo 1. Temporarily tighten the mounting bolts. NOTE: The
bracket must fit squarely against the mount bosses on the
upright. Inspect for interference from casting irregularities,
machining ridges, burrs, etc. Remove bolts one at a time, apply
red Loctite® 271 to the threads and torque to 30 ft-lb. Photo 1 Photo 2

• Orient the rotor (6) and the hat (7) as shown in Figure 1 and
Photo 3. Attach rotor to hat using bolts (9). Using an alternating
sequence, apply red Loctite® 271 to the threads, and torque to
25 ft-lbs.

•Slide the rotor registration adapter (5) onto the axle register on
the axle hub with the smaller O.D. facing toward the rotor/hat
(6/7), Photo 4. Slide the hat/rotor assembly onto the axle hub. Small
O.D.
NOTE: The hat must fit flush against the axle hub flange or toward
rotor/hat
excessive rotor run out may result. Install three lug nuts (finger
tight) to keep the hat/rotor assembly in place while continuing
with the installation.
Photo 3 Photo 4
•NOTE: Please reference the caution statement at the beginning (Generic example shown)
of the assembly instructions. This kit contains distinct right and
left hand calipers that must be mounted in a specific direction, as
described below. Mount the caliper (10) onto the caliper
mounting bracket (1) using bolts (12) and washers (11), as
shown in Figure 1. Initially place two .035” thick shim (13) on
each bolt between the caliper and the bracket, Photo 5. Ensure
that the caliper is mounted so the largest pistons are at the rotor
exit end of the caliper, in relation to the direction of rotor rotation.
Temporarily tighten the mounting bolts and view the rotor (6)
through the top opening of the caliper. The rotor should be
centered in the caliper, Photo 6. If not, adjust by adding or
subtracting shims between the bracket and the caliper. Always
use the same amount of shims on each of the two mounting Photo 5 Photo 6
bolts. NOTE: The end of each bolt must be flush with or slightly
protruding from the head of the clinch nut, as shown in Figure 3.
If necessary place spare shims between washer (11) and caliper
mounting ear to achieve the proper clinch nut engagement.
Once the caliper alignment and clinch nut engagement are
correct, remove the mounting bolts and caliper.

• Remove the two pad retaining pins from the caliper (10) by carefully popping out the pin retaining
clips and sliding out the pins. Insert the brake pads (14) into the caliper from the bottom, Figure 1
and Photo 7, with the friction material facing the rotor. Secure the brake pads in place with the pad
retaining pins and clips, Photo 8. Reinstall the caliper onto the caliper mounting bracket. Apply red
Loctite® 271 to bolt threads (12), and torque to 40 ft-lb.

Photo 7
Page 4
 Assembly Instructions (Continued)
•Temporarily install wheel and torque lug nuts to manufacturer’s END OF
specification. Ensure that the wheel rotates freely without any CLINCH NUT

interference.
END OF BOLT

•NOTE: OEM rubber brake hoses generally cannot be adapted to HEAD

OF BOLT
Wilwood calipers. The caliper inlet fitting is a 1/8-27 NPT. The CORRECT
END OF BOLT IS FLUSH WITH, OR SLIGHTLY
preferred method is to use steel adapter fittings at the caliper, PROTRUDING FROM END OF CLINCH NUT

either straight, 45 or 90 degree and enough steel braided line to

END OF
allow for full suspension travel and turning radius, lock to lock. CLINCH NUT

Carefully route hoses to prevent contact with moving Photo 8

suspension, brake or wheel components. NOTE: Wilwood END OF BOLT
hose kits are designed for use in many different vehicle HEAD
OF BOLT
applications and it is the installer's responsibility to properly route WRONG
and ensure adequate clearance and retention for brake hose END OF BOLT IS BELOW END OF CLINCH NUT

components. Wilwood offers a brake flex line hose kit to fit this END OF
CLINCH
application, order P/N 220-11751. Hose kits include hoses, fitting, NUT

etc., all in one package for this application.

END OF
•NOTE: Specified brake hose kits may not work with all Years, Makes and Models of vehicle that this HEAD BOLT
OF BOLT
brake kit is applicable to, due to possible OEM manufacturing changes during a production vehicle's WRONG
END OF BOLT IS PROTRUDING TOO FAR
life. It is the installer's responsibility to ensure that all fittings and hoses are the correct size and FROM END OF CLINCH NUT AND MAY
INTERFERE WITH MOVING PARTS
length, to ensure proper sealing and that they will not be subject to crimping, strain and abrasion from
vibration or interference with suspension components, brake rotor or wheel. Figure 3. Clinch Nut
Engagement Diagram
•In absence of specific instructions for brake line routing, the installer must use his best professional
judgment on correct routing and retention of lines to ensure safe operation. Test vehicle brake system
per the 'minimum test' procedure stated within this document before driving. After road testing, inspect
for leaks and interference. Initially after install and testing, perform frequent checks of the vehicle
brake system and lines before driving, to confirm that there is no undue wear or interference not
apparent from the initial test. Afterwards, perform periodic inspections for function, leaks and wear in
a interval relative to the usage of vehicle.

• Bleed the brake system, referring to the additional information and recommendations on page 6 for proper bleeding instructions. Check
system for leaks after bleeding.

• Install the wheel and torque lug nuts to manufacturer’s specifications.

Balancing the Brake Bias on 4 Wheel Disc Vehicles

•OE Style or Single Mount Race Pedal with Tandem Outlet Master Cylinder:
Front to rear caliper piston sizes, rotor diameters, and pad compounds must be initially configured to provide the correct range of vehicle
bias when using a single bore / tandem outlet master cylinder. If excessive rear brake bias is experienced, an in-line adjustable
proportioning valve can be used to decrease the rear line pressure to help bring the vehicle into balance. If excessive front brake bias
is experienced, first consideration should be given to increasing the rear brake bias to bring the vehicle into overall balance.

•Race Pedal with Dual Master Cylinders and Balance Bar:

Master cylinders must be sized to match the calipers and allow the pedal balance bar to operate near the center of its travel. If it is not
possible to fine tune the bias within the adjustable range of the balance bar, then consideration must be given to changing a master
cylinder bore size or some other aspect of the brake system to bring the car into balance. Larger bore master cylinders will generate
less pressure while decreasing pedal travel. Smaller bores master cylinders will generate higher line pressures with an increase in pedal
travel.

Page 5
 Additional Information and Recommendations
•Fill and bleed the new system with Wilwood Hi-Temp° 570 grade fluid or higher. For severe braking or sustained high heat operation,
use Wilwood EXP 600 Plus Racing Brake Fluid. Used fluid must be completely flushed from the system to prevent contamination.
NOTE: Silicone DOT 5 brake fluid is NOT recommended for racing or performance driving.

•To properly bleed the brake system, begin with the caliper farthest from the master cylinder. Bleed the outboard bleed screw first, then
the inboard. Repeat the procedure until all calipers in the system are bled, ending with the caliper closest to the master cylinder.
NOTE: When using a new master cylinder, it is important to bench bleed the master cylinder first.

•If the master cylinder is mounted lower than the disc brake calipers, some fluid flow back to the master cylinder reservoir may occur,
creating a vacuum effect that retracts the caliper pistons into the housing. This will cause the pedal to go to the floor on the first stroke
until it has “pumped up” and moved all the pistons out against the pad again. A Wilwood in-line two pound residual pressure valve,
installed near the master cylinder will stop the fluid flow back and keep the pedal firm and responsive.

•Test the brake pedal. It should be firm, not spongy and stop at least 1 inch from the floor under heavy load.
If the brake pedal is spongy, bleed the system again.

If the brake pedal is initially firm, but then sinks to the floor, check the system for fluid leaks. Correct the leaks (if applicable) and
then bleed the system again.

If the brake pedal goes to the floor and continued bleeding of the system does not correct the problem, a master cylinder with
increased capacity (larger bore diameter) will be required. Wilwood offers various lightweight master cylinders with large fluid
displacement capacities.

•NOTE: With the installation of after market disc brakes, the wheel track may change depending on the application. Check your wheel
offset before final assembly.

•On some models of disc brake spindles there are “ears” where the OEM calipers were mounted and these “ears” interfere with the
assembly of the Wilwood disc brake kit. If it becomes necessary to remove these “ears”, remove as little as possible being careful not
to cut away any of the mounting holes that may be required to bolt on the caliper mounting bracket.

•If after following the instructions, you still have difficulty in assembling or bleeding your Wilwood disc brakes, consult your local chassis
builder, or retailer where the kit was purchased for further assistance.

Page 6
Brake Testing

WARNING • DO NOT DRIVE ON UNTESTED BRAKES

BRAKES MUST BE TESTED AFTER INSTALLATION OR MAINTENANCE
MINIMUM TEST PROCEDURE

• Make sure pedal is firm: Hold firm pressure on pedal for several minutes, it should remain in position without
sinking. If pedal sinks toward floor, check system for fluid leaks. DO NOT drive vehicle if pedal does not stay firm
or can be pushed to the floor with normal pressure.

• At very low speed (2-5 mph) apply brakes hard several times while turning steering from full left to full right, repeat
several times. Remove the wheels and check that components are not touching, rubbing, or leaking.

• Carefully examine all brake components, brake lines, and fittings for leaks and interference.

• Make sure there is no interference with wheels or suspension components.

• Drive vehicle at low speed (15-20 mph) making moderate and hard stops. Brakes should feel normal and
positive. Again check for leaks and interference.

• Always test vehicle in a safe place where there is no danger to (or from) other people or vehicles.

• Always wear seat belts and make use of all safety equipment.

Pad and Rotor Bedding

BEDDING STEPS FOR NEW PADS AND ROTORS – ALL COMPOUNDS
Once the brake system has been tested and determined safe to operate the vehicle, follow these steps for the bedding of all new pad
materials and rotors. These procedures should only be performed on a race track, or other safe location where you can safely and
legally obtain speeds up to 65 MPH, while also being able to rapidly decelerate.

• Begin with a series of light decelerations to gradually build some heat in the brakes. Use an on-and-off the pedal technique by
applying the brakes for 3-5 seconds, and then allow them to fully release for a period roughly twice as long as the deceleration cycle.
If you use a 5 count during the deceleration interval, use a 10 count during the release to allow the heat to sink into the pads and
rotors.
• After several cycles of light stops to begin warming the brakes, proceed with a series of medium to firm deceleration stops to
continue raising the temperature level in the brakes.
• Finish the bedding cycle with a series of 8-10 hard decelerations from 55-65 MPH down to 25 MPH while allowing a proportionate
release and heat-sinking interval between each stop. The pads should now be providing positive and consistent response.
• If any amount of brake fade is observed during the bed-in cycle, immediately begin the cool down cycle.
• Drive at a moderate cruising speed, with the least amount of brake contact possible, until most of the heat has dissipated from the
brakes. Avoid sitting stopped with the brake pedal depressed to hold the car in place during this time. Park the vehicle and allow the
brakes to cool to ambient air temperature.

COMPETITION VEHICLES
• If your race car is equipped with brake cooling ducts, blocking them will allow the pads and rotors to warm up quicker and speed up
the bedding process.
• Temperature indicating paint on the rotor and pad edges can provide valuable data regarding observed temperatures during the
bedding process and subsequent on-track sessions. This information can be highly beneficial when evaluating pad compounds and
cooling efficiencies.

Page 7
 Pad and Rotor Bedding (Continued)
POST-BEDDING INSPECTION – ALL VEHICLES
• After the bedding cycle, the rotors should exhibit a uniformly burnished finish across the entire contact face. Any surface irregularities
that appear as smearing or splotching on the rotor faces can be an indication that the brakes were brought up to temperature too
quickly during the bedding cycle. If the smear doesn’t blend away after the next run-in cycle, or if chatter under braking results,
sanding or resurfacing the rotors will be required to restore a uniform surface for pad contact.

PRE-RACE WARM UP
• Always make every effort to get heat into the brakes prior to each event. Use an on-and-off the pedal practice to warm the brakes
during the trip to the staging zone, during parade laps before the flag drops, and every other opportunity in an effort to build heat in
the pads and rotors. This will help to ensure best consistency, performance, and durability from your brakes.

DYNO BEDDED COMPETITION PADS AND ROTORS

• Getting track time for a proper pad and rotor bedding session can be difficult. Wilwood offers factory dyno-bedded pads and rotors
on many of our popular competition pads and Spec 37 GT series rotors. Dyno-bedded parts are ready to race on their first warm
up cycle. This can save valuable time and effort when on-track time is either too valuable or not available at all, Dyno-bedding
assures that your pads and rotors have been properly run-in and are ready to go. Contact your dealer or the factory for more
information on Wilwood Dyno-Bedding services.

NOTE:
NEVER allow the contact surfaces of the pads or rotors to be contaminated with brake fluid. Always use a catch bottle with a hose to
prevent fluid spill during all brake bleeding procedures.

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Associated Components
PART NO. DESCRIPTION
260-13706 Wilwood Residual Pressure Valve (2 lb for disc brakes)
260-13707 Wilwood Residual Pressure Valve (10 lb for drum brakes)
260-8419 Wilwood Proportioning Valve, Knob Style
260-8420 Wilwood Proportioning Valve, Lever Style
260-11179 Wilwood Combination Proportioning Valve with Brake Light Switch
290-0632 Wilwood Racing Brake Fluid (Hi-Temp° 570) (12 oz)
290-6209 Wilwood Racing Brake Fluid (EXP 600 Plus) (16.9 oz)
340-13831 Wilwood Floor Mount Brake Pedal (with balance bar)
340-13832 Wilwood Swing Mount Brake Pedal (with balance bar)
260-6764 Wilwood 3/4 inch High Volume Aluminum Master Cylinder
260-6765 Wilwood 7/8 inch High Volume Aluminum Master Cylinder
260-6766 Wilwood 1 inch High Volume Aluminum Master Cylinder
260-4893 1-1/16 inch Tandem Master Cylinder (aluminum housing)
250-2406 Mounting Bracket Kit (tandem master cylinder)
260-8555 Wilwood 1 inch Aluminum Tandem Chamber Master Cylinder
260-8556 Wilwood 1-1/8 inch Aluminum Tandem Chamber Master Cylinder
220-11751 Stainless Steel Braided Flexline Kit, Miata Front 16 Inch

Wilwood Disc Brakes • 4700 Calle Bolero, Camarillo, CA 93012 Phone 805 / 388-1188 • Fax 805 / 388-4938
DS-1022DREV DATE: 08-12-19 www.wilwood.com • E-mail Additional Assistance: [email protected]