ECV M1151A1 Wilwood Brake Calipers, Rotors, and Half shaft assembly HELP!

[Mstng65HummrMan]

I won a GovPlanet M1151A1 in non-running condition in June with a bunch of parts ”Harvested”. The Propeller Shafts were pulled and thrown in the cabin with Ujoints missing the caps, the Start Box and wire harness coupler was arc welded and fried, TCM and box missing, left rear seat missing, Starter missing, Start Switch missing, Coolant Temp Gauge missing, rear brake light assembly missing, Alternator mount bolts were loose with the rear support bracket lower engine bolt sheared, Serpentine belt and tensioner missing, and various fittings from the transmission were also gone.

I have sourced almost all the known missing parts, including a FANTASTIC CamoTekSystems Keyed Manual Glow Plug Start Box, New TCM w box, obtained new Exide Super Start 6TMF batteries from Orielly’s Auto Parts (522 bucks for both!), changed the thick smelly black pudding oil, drained the power steering fluid (as a result of popping the hose on the pump and dumping a huge amount on the shop floor trying to secure that Alternator mount bolt) and installed a new Transmission pan, filter, seal, gasket, pan bolts, and Dexron III (or so it says) Valvoline Transmission fluid. A bunch of missing bolts and nuts for clips, brackets, clamps, exhaust flanges, thermostat housing, Transfer Case Safety Wire assembly, coolant hoses, and many others were obtained from Ace Hardware over dozens of visits.

Got er off the delivery truck Aug 8th, and after much toil, fixin, and plenty of dollars in the swear jar on Sept 22nd she was powered on, Glow plugs manually charged, and she fired immediately!! All gauges showed functional and even has more than half a tank of fuel!!! (Drained some into a glass gar to check and appears good with no contaminants or water). Lights all work too.

Another area of issue was the braking system was missing the front left components. I had to get a NOS Willwood ECV 4 Piston Caliper, a NOS Vented 12 inch Rotor (USA OEM), New Pad kit (USA OEM) new Brake lines and caliper fitting, and new half shaft/rotor bolt and double lock washers from Hummer Parts Guy to complete the missing component from the front left wheel brake system. I got it all reinstalled and tried to tighten the caliper mount bolts which caused the caliper to come in contact with the rotor and lock up the front left wheel, half shaft, and rotor. I loosened the bolts until the rotor and wheel rotated and noticed a gap between the caliper and bracket.

My question is, are the calipers mountable all corners or front rear left right specific. From my research it should be good all corners. Also, can the rotor be installed flipped? Should the inside of the rotor hat be worn by the Differential mount flange, or should the Half Shaft flange be on the inside of the rotor hat? I think I may have it reversed.

Does the Caliper mount tabs go inside the brake mount bracket closer to the differential, or on the other side towards the wheel?

Please send any install pics or if you can clarify if the top of the brake rotor hat should face the half shaft or the differential.

One more question. Can the Power Steering Reservoir to Power Steering Pump rubber hose (3/4” x 4”) be replaced with fuel line hose in a pinch, or is it required to be the sleeved/bonded high pressure Power Steering hose? Pics attached of the hose in question

It seems as though the mechanics working on my M1151A1 forgot to insert the metal Power steering reservoir to pump tube into the Pump hose and just tightened away on the hose clamp! Hose popped off as I was trying to secure the loose alternator mount bolt under the thermostat housing causing quite the mess on the shop floor.

Thanks very much, cant wait to get this beast back on the trails!!!!!

 

[Mogman]

Welcome to the SS forums!!!

 

[Mstng65HummrMan]

Thank you very much!

 

[Gcelevator]

Welcome, keep us posted.

 

[Mogman]

As far as the way the brakes are set up you have a perfect example on the other side of the truck.
All power steering return hoses should be replaced with power steering return hose

 

[Mstng65HummrMan]

Thank you, I’ll inspect the passenger side caliper and rotor tomorrow. As for the Calipers are they front and rear interchangable, my part number is 6040401, 2530-01-565-9660 per Wilwood website it is a front ECV caliper.

I got the power steering hose and will put it on tomorrow as well Thanks!

 

[Mstng65HummrMan]

Turns out the ECV disc I purchased was incorrect. The correct rotor was discerned and sourced from HPG!

While waiting for the correct rotor to arrive and with the M1151A1 up on jack stands, I worked on other items needing attention. I installed the rebuilt Propeller Shafts with the new Ujoints and hardware, tightened the loose exhaust system bolts and replaced the missing ones, checked all transmission and transfer case coolant lines and clamps again, installed the 195 Thermostat, cleaned out the coolant lines from the overflow tank to radiator and cross tube , filled and flushed the system with water, drained and filled it again, and ran it up to temperature. Fan works, and the water pump and thermostat are operating without leaks.

As far as I can tell, seems like the small leak coming from the rear of the torque converter was the reason the USMC techs sidelined this M1151A1 and started stripping the good stuff off. I topped off the Transmission fluid, checked the engine oil for water contamination, and fired her back up. I ran through the gears a few times as she warmed up and came back to life. Took her off the jack stands and drove forward and reverse a few times. Everything seemed good so I drove around the facility for about a mile checking engine operation and general vehicle functionality. The gears and transfer case ranges are functional, power steering works great lock to lock figure 8s, and no leaks since return hose replaced and properly tightened. Parking break works very well, but the light stays on when it is completely disengaged, something I haven’t had time to sort out yet.

Next steps are removing the rocks from the AC Condensors fans and testing the AC operation, lubing all grease points, Geared Hub oil changes (Lucas 80w-90), Differential oil changes front and rear (Lucas 80w-90), and the Transfer Case Gear Oil change (AC Delco 10-4033 Manual Transmission Fluid is what was recommended, correct?). I gave each of the wheels a good side to side and back and forth manipulation while up on the jack stands to check for looseness and all seems good. Ill check those Jesus nuts in the near future. Armored windshields are ready to install, and I’m looking for the rear cabin armor and the turret cap if anyone has any extras! Also need rear x doors, got the fronts already.

It would be great to know the story on this one, anyone have info on 644646 Registration Number USMC M1151A1 send it my way please!

 

[Mogman]

The brake light is likely the brake proportioning valve, you can check this by unplugging the wire from the valve.

 

[Mstng65HummrMan]

I appreciate that advice, will do and thanks!

 

[Retiredwarhorses]

Brake lamp on is low brake fluid or bad brake switch on the ebrake lever, the ball get corroded and won’t move…

 

[Mstng65HummrMan]

Wel the reservoir is dry, front left rotor, caliper, and lines were gone When I got it. I have everything replaced waiting on the rotor to finish assembly and fill and bleed. Ill check the light when It is back together!

What flush fluid would you use to clean out the lines?

Thanks again all for the help with this project truck!

 

[Mogman]

Wel the reservoir is dry, front left rotor, caliper, and lines were gone When I got it. I have everything replaced waiting on the rotor to finish assembly and fill and bleed. Ill check the light when It is back together!

What flush fluid would you use to clean out the lines?

Thanks again all for the help with this project truck!

I thought you already had the brakes put back together, of course you are going to have a brake light!!!