New Front Calipers - Brake Line Wont Fit

[Ol'Blue]

Installing new WH Brake Calipers on a Dana 44 from a 77. The brake line end wont fit between the caliper and the knuckle. Its very close but wont quite let me get the bolt through. I could grind off the small lip on the brake line end, but wanted to post up before doing that. Any ideas? Thanks,

 

[thegreatjustino]

Take the caliper off, install the line, reinstall the caliper.

 

[DirtDonk]

I thought the lip located the hose block on the caliper. Meaning it would be flipped over from your positioning.
Does it not fit that way? And you verified for certain that your left and right calipers are on the correct sides? Bleeders up!

Been awhile, so I'll go look at mine when it stops raining.

paul

 

[DirtDonk]

Nevermind. I remember thinking the same thing I just said when I put mine on. Figured the flange should fit over the caliper, but it did not.
Mine are close too, but definitely have a gap. Pics coming...

 

[DirtDonk]

Driver's side:

Passenger side:

Bad pic of the passenger side. There is more clearance than it looks like there. Pretty much the same both sides.

 

[DirtDonk]

If you try Justin's way and the angle just does not allow you to fit the hose and not hit the knuckle (looks like there is enough room) then there is nothing that says you can't cut off the flange.
Just be sure to close the opening before you do any grinding or cutting. Definitely don't want debris in that area.

Paul

 

[Ol'Blue]

I took caliper lock bolt and pin out then attached the brake line. Hammering the pin back in was a little sketchy but seem to go together okay but the brake line is still hitting the knuckle. Hopefully not binding too much and no leaks when I bleed them.....thanks for the help.

 

[DirtDonk]

I don’t think that’s gonna work. Yes it probably won’t lock things up, but no it’s not supposed to touch anything. The caliper should be free floating so it can slide on the mount.

And when you say hammering in, does it take a lot of pressure to put the locking pin in? It should just take the light taps and should not have to be hit very hard to slide in.

 

[Ol'Blue]

Yes the pin is

I don’t think that’s gonna work. Yes it probably won’t lock things up, but no it’s not supposed to touch anything. The caliper should be free floating so it can slide on the mount.

And when you say hammering in, does it take a lot of pressure to put the locking pin in? It should just take the light taps and should not have to be hit very hard to slide in.

 

[Ol'Blue]

Good point Paul and yes it is tough to get the pins in but rubber mallet on the caliper will move it back and forth very slightly. I think if I grind down the lip on the brake hose end enough just to make sure it isn't catching, I should be good? Here are a few more pics. The new calipers look to match the old and I compare the pins as well and all look to match.

 

[DirtDonk]

Do your new hoses have shoulder flanges on both sides? It looks like your calipers have a flat edge for it to hang over. If they have flanges on both sides I would definitely grind one off.
If not, it almost looks as if your hose will work when flipped around.

Does not sound like your caliper is too tight, so that part sounds good to go.

 

[Ol'Blue]

The hoses are existing but after market and don’t have the flange on both sides. The bolt hole in the block that mounts to the caliper is off set slightly to one side so you can’t flip it. Hopefully this pics will show.

 

[WILDHORSES]

First time I have seen this. Like Paul said we don't want the hose fitting hitting the knuckle is any case. I'm not opposed to taking off some materiel from that end fitting but have never had to. This is a weird one for sure.

Jim

 

[Ol'Blue]

Crazy right? I ground them down and have good clearance now. Thanks Paul and Jim

 

[Ol'Blue]

Installed the wheels today and the brake caliper hit the balancing weights glued to in inner side of the rims. They hit right where the caliper clip is the locks the caliper in place. Knocked all the weights off. Don't think its a big deal. I can have the wheel balance and weights relocated but thought it was worth mentioning. Maybe a slightly different casting with these calipers.

 

[DirtDonk]

No, a very common issue ever since stick on weights came about.
Less common after wheels started getting larger in diameter, oh, and after tire installers got the message.