INSTALLATION INSTRUCTIONS FOR THE ½ TON TRUCKS STUDEBAKER REAR DISC BRAKE KIT 

When all else fails, read these instructions!!!

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TURNER BRAKE
1953 thru 1964 STUDEBAKER UNDER FLOOR
DUAL MASTER CYLINDER PACKING LIST
DISC – DISC COMBINATION

1 - LEFT REAR CALIPER MOUNTING BRACKET W/SPACERS

1 - RIGHT REAR CALIPER MOUNTING BRACKET W/SPACERS

8 - 3/8 x 3 ¼   GRADE 8 HEX HEAD BOLTS *

8 - 3/8   LOCK WASHERS

8 - 3/8 GRADE 8 LOCKNUTS

16 - 3/8 WASHERS

4 - 12 mm Caliper bolts

4 - 12mm Lock Washers

4 - 12mm Flat Washers

2 - BRAKE HOSE’S WITH SEALING WASHERS

2 - BANJO BOLTS H-5381

1 - LEFT LOADED REAR CALIPER

1 - RIGHT LOADED CALIPER

1 - LEFT ROTOR

1 - RIGHT ROTOR

10 - NEW WHEEL STUDS   610-475

4 -  LARGE WIRE TIES

1 -  SET COMPLETE INSTRUCTIONS

*NOTE, EVEN THOUGH LOCK WASHERS ARE PROVIDED IN THIS BRAKE KIT, 
WE HIGHLY RECOMMEND THE USE OF RED LOCTITE

Remove the stock rear brakes, as per the Studebaker shop manual; you will also need to remove the brake backing plates. NOW is a good time to pull the axles, re-pack the rear wheel bearings, and set the rear axle endplay, AS per the Studebaker shop manual.

 

Once the rear bearings are re-packed and the end play adjusted, you are ready to install the TURNER BRAKE rear disc brake brackets. These brackets are stamped LEFT & RIGHT, the left side is the driver’s side, and the right side is the passenger side!

 

Using the 6, 3/8” x 1 ¼” grade 8 bolts, assemble the bracket to the OUTSIDE of the rear axle flange, so the caliper will be up and behind the axle. using the stock seal, along with the supplied lock washers, lock nuts, and tighten these bolts to 50 ft. lbs. of torque. See Photo 1

Next you will need to remove the brake drum from the stock hubs. Being careful not to damage the hub or drum, even though you are not going to use the drums, they still have some value!! This may be something you may want to have a machine shop do for you, as this can damage both the drum and hub!

 

DO NOT THROW THEM AWAY!

 

Once you have the hubs separated from the drums, press the new studs into your existing hubs, Re-install the hubs and torque them as per the Studebaker shop manual. Be sure to set the axle end play per the Studebaker shop manual! The rotors that are supplied are interchangeable. 
 

Once the hubs have been separated from the hubs, and new studs installed, install the rotor/hub assembly onto the axle.
 

Now using the 1/8” spacer between the caliper (IF NEEDED) and the caliper bracket, and using 2 14MM bolts, lock washers and washers, Install the calipers onto the brackets, making sure the bleeder screw is at the top! Using some RED Loctite, Torque these bolts to 55 Foot Lbs. 
 

TEST FOR PROPER OPERATION OF THE EMERGENCY BRAKE, YOU NEVER KNOW WHEN YOUR LIFE MAY DEPEND ON IT!

To keep the emergency brake adjusted and in proper working condition on your
TURNER BRAKE rear disc conversion,

 

ALWAYS SET YOUR EMERGENCY BRAKE WHEN PARKING!

 

Now it is time to install the rear brake hoses, Install the inline brass fitting to the original steel line, You WILL need to cut and flare the original steel line to accept the brass fitting.   and tighten. Next, install the brake hose to the brass fitting and tighten. (The hose will run under the axle tube and back to the caliper) Then using one of the banjo bolts and two of the crush washers included in this kit, place a crush washer on one of the banjo bolts, the banjo bolt through the brake hose, another crush washer, then into the caliper. And torque the banjo bolts to 32 foot pounds or torque!

 

The best way to bleed the brakes is to use good ole” gravity! Fill the master cylinder, and open the right rear bleeder screw, and let the brake fluid flow through! This will eliminate finding a second person! After the right side is done, re fill the master cylinder, and repeat the same for the left side. However, once you are done with the gravity bleed method, we do recommend that you get someone to pump the brakes to be sure ALL of the air is gone from the system.

 

CHECK FOR LEAKS, AND ANY POSSIBLE INTERFERANCE WITH THE BRAKE HOSE’S

 

Use the enclosed tie wraps to secure the stock steel brake line to the axle tube.
 

YOUR STOCK STUDEBAKER WHEELS MAY NOT CLEAR THE CALIPERS AND BRACKETS! YOU MAY HAVE TO USE EITHER GM WHEELS OR AFTERMARKET WHEELS

 

Now you are ready to install the emergency brake cable! 


Remove the stock emergency brake cable, as per the Studebaker shop manual, and install the emergency brake cable.* Once the cable is loosely in place, before attaching the front of the cable, it is much easier to attach the cable to the calipers. Once that is done, finish attaching the cable to the emergency brake handle.

 

Adjustment of the TURNER BRAKE rear disc brake emergency brake cable is accomplished using the original Studebaker adjustment. Take up the slack in the rear cable by tightening the front parking brake cable adjustment nut. PULL or step on the emergency brake THREE times and RELEASE, check at the rear calipers, look at the emergency brake lever, be sure that it is back against the stop when released, if it is, Then check the position of the lever when the emergency brake is engaged, it should be pulled forward and you should not be able to turn the wheels. 
 

*For all applications, please download the paperwork.

 

We also recommend that you check your installation each time you drive for the first few days, or 500 miles this is to insure that there are not interferences with the brake hose, lines or emergency brake cables.

 

As of the current time we have not found anybody to make up custom Emergency Brake cables, our supplier decided to retire!
 

EMERGENCY BRAKE CABLES FOR ALL APPLICATIONS!

THERE IS AN EXTRA CHARGE FOR THIS CABLE ON ALL KITS.

 

We no longer stock the emergency brake cable for use with the TURNER BRAKE rear disc interchange kit., you will need to measure the difference in the stock emergency brake cable, and determine what the correct length needs to be. Usually it will need to be shortened, both in total length and the spring at the end of the cable.

 

You need to take the correct measurements, fill out the following form, and mail it back to TURNER BRAKE. We will forward that measurement that YOU provide to our manufacturer, who will then drop ship the cable back to you. NOT AVAILABLE AT THIS TIME!

 

IF YOU SEND AN INCORRECT MEASUREMENT, WE SEND YOU AN INCORRECT CABLE! IF YOU HAVE ANY QUESTIONS ABOUT THIS, PLEASE CONTACT US BEFORE YOU SEND IN THE MEASUREMENTS FOR THE CABLE!

 

We understand this is a slight inconvenience, but, in trying to accommodate as many different vehicles as possible, We are still looking to get a supplier for the emergency brake cables!!
 

HOW TO MEASURE THE EMERGENCY BRAKE CABLE

We need the measurement between the supports on the frame and the caliper bracket, for the shielded part of the cable.  (A to B)
 

We also need the total length of the cable from end to end. (C to C) It is easier to use the stock cable and attach it on one caliper, then WITH THE CENTER ADJUSTMENT  (X) AT ITS LONGEST, (nut screwed out all the way to the end of the linkage) Pull the cable until it is SNUG and measure how much will need to be either added or subtracted from your cable. We must know the original length of your cable, and the length you want us to make your new cable.  The measurement from (B to C) is 4 inches. This will not change. Once we receive the back sheet, we will forward it on to the manufacturer. They will drop ship it directly to you.
 

A

Cable bracket on frame caliper

B

Cable bracket on caliper

C

lever on X center adjustment

A

Cable bracket on frame caliper

B

Cable bracket on caliper

C

lever on caliper center adjustment

TURNER BRAKE
STUDEBAKER HALF TON TRUCK
REAR DISC BRAKE KIT PARTS LIST

RAYBESTOS - 780623R - ROTORS (2)

RAYBESTOS RIGHT CALIPER - FRC12003N

RAYBESTOS LEFT CALIPER - FRC12004N

DORMAN WHEEL STUDS - 610-475 (10)

Hose’s WAGNER - BH38160 (2)

RAYBESTOS BANJO BOLTS - BH38160 (2)

RAYBESTOS BRAKE PADS - MGD 1719CH

INSTALLATION INSTRUCTIONS FOR THE 3/4 TON TRUCKS 8 Lug

Before you begin, read and follow these instructions, Your SAFETY as well as others depends on proper installation of this kit.

 

Your must raise the vehicle and properly support it BEFORE starting any repairs!

 

Remove the existing brakes as well as the backing plates, by following the Studebaker Shop Manual. (DO NOT throw them away, as somebody somewhere may need them)

 

Once the original brakes have been removed, you will need to remove the inner and outer bearing races, and install them into the new rotor. The new rotor has a bearing race spacers added so that the original wheel bearings will fit and can be utilized. Clean and re-pack the wheel bearings following the Studebaker shop manual procedures. Install the grease seals on the two rotors and set theses assemblies aside until needed.

 

Now install the brackets, they are marked LEFT and RIGHT (Left being the drivers side, and Right being the passenger side) Look at how the brackets are pre-assembled with the short spacers on the bolts. Using RED Loctite along with the lock washers and lock nuts, torque these bolts to 50 ft lbs. NOTE: YOU WILL NEED TO INSTALL THE 90 DEGREE GREASE FITTINGS FIRST!

 

Once that is completed, you are ready to install the rotor and bearing assemblies. Be sure to follow the Studebaker shop manual for proper adjustment of the wheel bearings.

 

The Calipers are also marked LEFT and RIGHT, Install them to the proper side, making sure that the bleeder screw is at the TOP of the caliper. Torque the caliper pins to 15 ft lbs.

 

Now attach the brake hoses, and torque the banjo bolts to 10 ft lbs. Again, following the Studebaker shop manual, properly bleed the complete brake system.

 

IF you are using the original Studebaker master cylinder, you WILL need to remove the original check valve from the master cylinder. (a separate sheet is included)

 

You will also need to use the included RED 10# valve to the rear drums, and the BLUE 2# valve to the fronts. This will help with a good pedal.

 

IF you are converting to a dual master cylinder, the residual check valves, have been removed already.

 

Be sure to properly install the wheels and torque the lug nuts to the proper torque specification found in the Studebaker shop manual.
 

Failure to properly install this kit could result in serious injury to you or others or possible death! Your life depends on proper installation of this product.

HOW TO REMOVE A RESIDUAL VALVE FROM A MASTER CYLINDER

[1] Master cylinders used in trailer Hydraulic surge brake couplers are available either fitted with a residual valve [check valve], or without the residual valve in place. If a trailer braking system uses drum brakes the master cylinder should be equipped with a residual valve. This check valve maintains approximately 10# to 15# of hydraulic pressure [priming pressure] on the hydraulic circuit, from the master cylinder out to the drum brake wheel cylinders. This reduces the time of brake activation, by overcoming the pressure created by the drum brake return spring.

 

[2] If , however the trailer is to be equipped with DISC Brakes the 10# to 15# pressure created by the residual valve will partially activate the disc brakes, during highway travel , causing brake overheating and failure.

 

[3] If the master cylinder is equipped with a residual valve it will be necessary to remove the residual valve to eliminate it’s hydraulic effect on the disc brakes. WARNING: Puncturing the residual valve can damage components internal to the master cylinder, and should not be attempted.

 

[4] To remove the residual valve, proceed as follows. As per the drawing below, remove the rubber dust boot exposing the Snap Ring. Compress the snap ring and remove. Be aware that the return spring is under compression and upon removal of the snap ring, the piston may shoot out of the cylinder. You should use some counter acting force to retard this problem. Upon removal of the snap ring, remove the piston, and the return spring. As the return spring is removed you will find the Residual valve inserted into, and thereby affixed to the return spring. Snap the Residual valve out of the return spring, then reassemble the remaining components in the reverse order from disassembly. Note that there is a thick rubber washer in the far end of the master cylinder tube that probably did not come out when the other components were disassembled. This is the washer that the residual valve previously sealed against. It is important that this washer be left in place in the master cylinder. Because of it’s thickness it will provide proper spacing for the length of the return spring to properly operate with the new disc brake assembly.

 

[5] Now, upon final assembly you can use the master cylinder with your disc brake system. 
 

**WARNING, DO NOT DRIVE ON UN-TESTED BRAKES**

BRAKES MUST BE TESTED AFTER INSTALLATION OR MAINTAINANCE
MINIMUM TESTING PROCEDURE

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

At very LOW speed, (2-5 mph) apply the brakes hard several times while turning the steering wheel from full left to full right, repeat several times. Remove the wheels, and check that NONE of the components are not touching, rubbing, or leaking.

Carefully examine ALL of the brake components, brake lines, and fittings for leaks and interference.

Make sure there is NO interference with the wheels, or suspension components.

Drive the vehicle at low speeds (15-20 mph) making moderate and hard stops. Your brakes should feel normal and positive, again check for leaks and interference.

ALWAYS test the 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 available safety equipment.

*****WARNING*****

Disc brakes should ONLY be installed by someone experienced and competent in the installation and maintenance of disc brakes.

If you are NOT sure of how to safely use this brake component or kit, you should not install or use this kit.

DO NOT “assume” anything! Improperly installed or maintained brakes are dangerous. If you are not sure, get help!

You can obtain additional information and get technical support by calling Turner Brake @ (317) 294-1492 or by visiting our website at www.turnerbrake.com

Use of Turner Brake Technical support does NOT guarantee proper installation of these products. It is not possible over the phone to understand of foresee all the issues that might arise in your installation.

ALWAYS test your brakes before driving!

Turner Brake Warranty

This Master Cylinder kit utilizes, a stock American made, modern brake parts from various automobile manufactures.

This kit is designed to adapt these modern parts to the stock Studebaker frame, without any permanent modifications to the frame. The finest quality parts have been assembled for this kit. All of the bolts lock washers, and lock nuts are of grade 8 aircraft quality, NOTHING LESS WILL DO!

 

The stock Studebaker Master Cylinder is held on by 2 3/8 x 5 3/4 grade 5 bolts with lock washers. This kit utilizes 2, 3/8 x 3 1/4 grade 8 bolts, with lock washers and lock nuts. BE SURE TO USE RED LOCTITE ALONG WITH THE LOCK WASHERS AND LOCK NUTS!!

 

Also included in this kit are the proper torque specifications for each set of bolts, THESE MUST ALSO BE USED!!  A competent professional mechanic should install this kit. THE PURCHASER IS RESPONSIBLE FOR PROPER INSTALLATION OF THIS PRODUCT.

LIMITED WARRANTY

TURNER BRAKE, and it's affiliates, warrants to the original purchaser that it's product shall be free from defects in materials and workmanship for a period of ninety (90) days from the date of original purchase. All claims shall be made by returning the product; FREIGHT PRE-PAID, with proof of purchase to TURNER BRAKE.

 

If found to be defective in material or workmanship upon inspection, TURNER BRAKE will repair or replace the defective product. In no event shall this warranty exceed the original purchase price of this product.

 

This warranty shall not apply to products subjected to accident, negligence, alteration, abuse, misuse, racing purposes, improper installation, or unsuited uses. Furthermore, TURNER BRAKE shall not be liable for any consequential, special or contingent damages or injury arising directly or indirectly from any defect in its goods or from use of goods, defective or not.

 

TURNER BRAKE'S only obligation will be to repair or replace material defects proven to be defective; neither seller nor manufacturer will be liable for any loss, injury, or consequential damages, arising from use or inability to use this product.

 

IT IS EXPRESSLY UNDERSTOOD AND AGREED THAT THIS WARRANTY SHALL BE IN LIEU OF ALL WARRANTIES OF FITNESS AND IN LIEU OF THE WARRANTY OF MERCHANTABILITY AND THERE ARE NO OTHER WARRANTIES EXPRESSED OR IMPLIED

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