PBR Caliper specs:
weight: 10.4 lbs (loaded)
piston diameter: 45x45mm dual piston.
In this article we are installing a PBR dual piston caliper brake kit.
Originally found on the 99+ models it gives a better than stock feel.
The PBR units can be found at a junker or from some specialty shops. This
is a "low budget" project which most people will be able to
afford and perform with home tools.
These PBR units are an almost bolt-on deal for 94-98 Mustangs, with minor
grinding required for the spindle. Fox body mustangs will have to use
the 94-98 spindle which will increase ackerman, but we wont cover the
Fox swap in this article.
94-98 SN95s can retain their stock 10.8 discs, but it would be a good
idea to swap them in favor of some Drilled or Slotted rotors. They are
also lighter (8 lbs) than the '94-98 cast calipers which will reduce unsprung
weight, and you get the benefit of the dual piston calipers!
PBR calipers and discs came from a 2002 Mustang GT with low miles so we
are keeping the discs and just have them resurfaced. Prior to installation
we cleaned and polished the calipers to improve the looks. The polishing
is no easy task, took us around 2 days but the calipers look like aftermarket
units with a distinct chrome look. We also painted the vents on the rotors
and center section.
take-off units come loaded with pads and brake lines. The '94+ Mustang
brake lines are side specific, so you cannot switch sides with them. The
'99+ Mustang lines are a direct bolt in for the 94-98 cars. The 94-95
spindles will have to be cleareanced for the dual piston 99+ calipers
mount the PBR calipers on the older '94-98 spindles, you need to shave
about 5mm off each "ear" of the caliper mounting bolt hole.
This can be done with a grinder very easily. It will take about 20 minutes
to complete both spindles.
Removal and Installation
- Remove one caliper at a time. The caliper is held onto the spindle
via a bracket. Two bolts may be accessed from behind the bracket. Support
the caliper/bracket assembly. Dont disconnect the hose yet.
- Remove the factory caliper mounts.
the rotors, if they have never been removed theres probably a locking
spider washer in a couple of the bolts. Remove them and discard. Give
a few blows with a rubber mallet to the rotors from behind. Rotate the
rotors as you do this.
- Grind around 5mm from each spindle as shown here.
Test-fit the PBR caliper mount.
- Install the PBR caliper mounts.
the stock calipers, their factory flex hose and hose mount from the
fender skirt mount. A plug or other temporary item should be used to
prevent the fluid from draining. If equipped with ABS, allowing the
system to run dry will require a factory type brake bleed procedure
to ensure no air has entered the system.
- Re-Install the rotors.
- Install the PBR flex hose, caliper and pads.
- Repeat for the other side.
complete, you can put the short length of tubing over the bleed screw
and open the bleed screw. Pour brake fluid into the master cylinder
reservoir so that it stays full enough to prevent air from entering
the lines. Watch the hose for fluid flow as gravity pulls the fluid
into the caliper and forces out the air. Close the bleed screw when
fluid begins to appear. Bleed the brakes as normal. One easy way is
to use a handheld vacuum pump setup at the caliper to draw out the fluid
which in turn clears air from the system.
It is time to take your ride for a spin, if you installed new pads follow
the manufacturer recommendations for break-in. If the brakes feel spongy
bleed them again.
Other upgrades to your brake setup will be to install braided lines,
this will improve the braking ability further.