Step-by-Step Guide to Installing Wilwood AERO6-DM Brake Kits

Installing AERO6-DM Direct-Mount Front Brake Kits from Wilwood

When truck enthusiasts hear the term “bolt-on” or “easy installation,” many will roll their eyes and may even back away from the claim, as they know it’s seldom true. While some performance brake kit installations can be a bit difficult and time-consuming, we want to show you in this installation that the AERO6-DM front kits from Wilwood Disc Brakes are not that difficult and do not take too much time at all. Besides some possible backing plate trimming (varies depending on the application) and brake line bleeding to finish the installation, they truly are bolt-on.

AERO6-DM 6-piston calipers were designed to directly mount to OE spindles to provide a large-capacity brake torque solution with large diameter well-vented rotors for heavyweight and extreme-duty vehicles. These direct mount kits for trucks and SUVs provide enhanced braking power with improved pedal feel and confidence to better handle towing and overlanding gear weight. Kits will fit most 17-inch (or larger) wheels and even bigger tire upgrades that aid your off-roading prowess.

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Installation should only be performed by persons with experience installing and properly operating disc brake systems.

The kits are fully compatible with OE master cylinder output and work with ABS setups. Wilwood’s OEM-style one-piece rotors provide maximum cooling for sustained-high-heat durability for those wanting to take advantage of added gear to make camping and overlanding safer and more enjoyable.

Follow along as we show you the key steps to install the AERO6-DM brake kit on a 3rd-generation Tacoma. Check out the many other year, make, model fitments for 4Runner, FJ, Lexus GX, Ford and Chevy trucks, Bronco, Jeeps, and SUVs at the Wilwood website.

Before beginning, verify wheel clearance using the diagram provided.

Wilwood Aero6-DM Brake Kit Parts List: Calipers, rotors, pads, SS flexlines, and step-by-step install instructions. Calipers are available in 26 powdercoat color options.

With the vehicle properly secured according to the manufacturer’s instructions, remove the wheel, disconnect the brake line at the chassis hard line and plug to prevent dripping, and then remove the OE caliper and brake hose.

Remove the OE rotor. Use bolts (not included) in any available threaded rotor holes to help break free stubborn rotors from the hub.

Remove any nicks or burs on the hub, upright, dust shield, and caliper mounting bosses. Clean and de-grease to provide smooth, clean surfaces.

Depending on the vehicle model, the dust shield may require trimming to provide adequate clearance. (The assembly instructions will provide details.)

Slide the rotor onto the hub, ensuring it is flush to prevent rotor runout. Install three lug nuts, and hand-tighten them to hold the rotor in place temporarily.

Insert the brake pads into the caliper (friction material facing rotor, yes, this needs to be said) and slide in the pad retaining pins to hold pads in place. Use a small punch and hammer to tap in the pin heads until fully seated.

Mount the proper left-hand or right-hand caliper (largest piston is at rotor exit in forward rotation) onto the mounting bosses of the upright using bolts and washers provided, apply red Loctite 271 and torque to provided value. Next, temporarily mount the wheel and torque to manufacturer’s specs and ensure the wheel rotates freely.

Attach the provided Wilwood flexlines to the caliper (note: OE rubber lines generally cannot be adapted to Wilwood calipers), and route to the existing hardline as shown in the instructions using the provided hardware. NOTE: Ensure hoses are routed to prevent contact with moving suspension, brake, or wheel components.

Bleed the brake system at the upward-facing bleed screw on each caliper. Refer to the installation instructions for proper procedure and double-check for leaks as instructed.