EPA-AA-TEB-511-82-10A
EPA Evaluation of the BRAKE-EZ Device Under
Section 511 of the Motor Vehicle Information and Cost Savings Act
by
Stanley L. Syria
August 1982
Test and Evaluation Branch
Emission Control Technology Divison
Office of Mobile Sources
U.S. Environmental Protection Agency
-------
EPA Evaluation of the BRAKE-EZ Device Under Section 511 of the Motor
Vehicle Information and Cost Savings Act
The Motor Vehicle Information and Cost Savings Act requires that EPA
evaluate fuel economy retrofit devices and publish a summary of each
evaluation in the Federal Register.
EPA evaluations are originated upon the application of any manufacturer
of a retrofit device, upon the request of the Federal Trade Commission,
or upon the motion of the EPA Administrator. These studies are designed
to determine whether the retrofit device increases fuel economy and to
determine whether the representations made with respect to the device are
accurate. The results of such studies are set forth in a series of
reports, of which this is one.
The evaluation of the Brake-EZ device was conducted after receiving an
application for evaluation by the manufacturer. The device is claimed to
reduce disc brake drag and thereby improve fuel economy and exhaust
emission levels as well as vehicle performance. Because this device is
intended to reduce wheel rotational drag, it is classified by EPA as a
road load modification device.
The following is the information on the device as supplied by the
applicant and the resulting EPA analysis and conclusions.
1. Title;
Application for Evaluation of BRAKE-EZ under Section 511 of the Motor
Vehicle Information and Cost Savings Act
2. Identification Information (as supplied by the applicant);
a.- Marketing Identification of the Product;
"Brake-EZ per attached literature." (Attachment A of this
evaluation)
b. Inventor and Patent Protection;
(1) Inventor
Robert W. LaWarre, Sr.
958 Kingswood Drive
Lima, OH 45804
(2) Patent
"Patents applied for October 7, 1980."
-------
c. Applicant:
(1) Name and address
EZ Line Products Corporation
1107 East Kibby Street
P.O. Box 35
Lima, OH 45802
(2) Principals
President - Ned LaWarre
Vice-President - Marketing - Timothy D. LaWarre
Secretary and Treasurer - Robert W. LaWarre, II
d. Manufacturer of the Product:
(1) Name and address
Precision Metalcraft Corporation
1107 East Kibby Street
P.O. Box 35
Lima, OH 45802
(2) 'Principals
President and Owner - Robert W. LaWarre, Sr.
Vice President and Treasurer - Betty E. LaWarre
Secretary - Joseph H. Weir
Description of Product (as supplied by Applicant);
a. Purpose;
"To reduce or eliminate disc brake drag which causes premature
brake wear, damage to rotors and reduction of gas mileage."
b. ' Theory of Operation;
"Device allows the caliper to find its own center over the
rotor, thereby reducing frictional drag of either inside or
outside pad contact to rotor when the brakes are not applied.
"The design or function of the caliper piston travel has not
been altered. The target was to gain control of the sliding
action so that the brake would function as originally intended.
"This control has been achieved through the use of noncorrosive
materials and new technologies in coatings and lubricants."
c. Construction and Operation;
"Enclosed herewith find samples of each kit currently available
in the market place."
-------
d. Specific Claims for the Product;
In addition to the claims aade in Section 3a above, each
merchandising package claims that the device reduces tire wear
and guarantees to increase mileage by 10 percent or your money
back.
e. Cost And Marketing Information:
The applicant stated (Attachment B of this evaluation) that,
"the suggested list price is $34.95 on all BRAKE EZ Kits
presently in production. The average installation time is .7 -
.8 hours. However, when installed during brake pad
installation, no additional labor should be charged." The
suggested list price compares to a high of $44.00 for General
Motors OEM parts and a low of $15.00 for Ford OEM replacement
parts.
"The kits are marketed through the normal automotive aftermarket
channels and national merchandisers-automotive service centers."
4. Product Installation, Operation, Safety and Maintenance (as supplied
by Applicant):
a. Applicability:
"Installation tips, service bulletins and application lists, in
catalog form, are enclosed (Attachments A and C of this
evaluation). Installation instructions and vehicle applications
are printed on the reverse side of kit packages (Attachment D of
thi s evaluation)".
b. Installation - Instructions, Equipment, and Skills Required;
"General instructions and vehicle application lists are printed
on the reverse side of the packaged kits (Attachment D of this
evaluation). No special tools or equipment are required for
installation. Common, mechanics hand tools are adequate for any
installation of the device, and average mechanical skills are
sufficient for a successful installation."
c. Operation:
"Device is self-contained and does not require adjustment or
control during operation. No instructions are required for
usage other than instructions to install the device."
d. Effects on Vehicle Safety;
"The reduction of destructive heat due to brake drag and the
reduction of brake drag itself gives better braking capabilities
(reduces brake fade) and better all around vehicle response.
This can only add to vehicle safety, whether it be city or
highway driving.
-------
"The parts which are replaced in the OEM assembly are not
different in design; thus, there is no additional safety hazard
than that which existed before installation."
e. Maintenance:
"Once this device is installed, no maintenance is required. It
is recommended the device be replaced when the disc brake pads
are replaced at the end of their wear life."
5. Effects on Emissions and Fuel Economy (submitted by Applicant);
a. Unregulated Emissions;
"It has not been determined what positive effect this device has
upon emissions due to the reduction in the rolling resistance of
the vehicle -after installation. This reduction in rolling
resistance does reduce engine output torque requirement at a
given MPH when compared to the output torque requirement at that
same MPH prior to the installation of the device.. This
reduction of torque equates to less engine and drive train wear
which ultimately increases the life of the vehicle."
b. Regulated Emissions and Fuel Economy;
"Ohio Highway State Patrol - Lieutenant Landis, Columbus, Ohio
(614) 466-5378. [This information was not provided with the
application. However, as a result of a reqvre-st by both EPA and
the applicant, a summary of the test results of the Ohio State
Highway Patrol was later sent to EPA and is included as
Attachment E.]
"United Telephone Company - Urban Thaman, Lima District Fleet
Maintenance Director, Lima, Ohio (419) 226-6293" [Attachment F
of this evaluation]
6. Testing by EPA;
EPA did not test the device for this evaluation because the test data
submitted by the applicant did not adequately support the claims made
for the device nor did it show the device to be superior to new OEM
parts.
7. Analysis
a. Identification Information;
. (1) Marketing Identification:
EPA finds no problems with the marketing title of the
device.
-------
(2) Patent Protection:
The applicant did not submit a copy of either the patent or
the patent application.
b. Description;
(1) The primary purpose of the device is to improve fuel
economy by reducing the vehicle's required road
horsepower. According to the applicant, this is
accomplished by reducing or eliminating disc brake drag.
It is known that vehicles which are equipped with disc type
brakes do experience seme degree of brake drag. Therefore,
should the BRAKE-EZ device be capable of reducing brake
drag, there may be some fuel economy benefits realized.
The benefits that may be realized when using the device
would need to be determined by actual testing.
(2) The theory of operation given in Section 3b of the
application was judged to be adequate. It appears the
device is intended to prevent corrosion on brake sliding
contact surfaces and thereby allow the calipers to move
freely.
(3) For the description of the device, the applicant referred
to the various samples submitted to EPA. Each sample was
enclosed on a bubble type merchandising display card.
Attachment G of this evaluation is a copy of one of the
sample kits. Because of the different brake systen designs
currently in use, the components contained within each
package differed from each other. The components appear to
duplicate the original brake parts in all respects except
for the coating which was found on all metallic surfaces.
It is assumed the coating material is the **noncorrosive
material" referenced in Section 3b. Whether the coating is
non-corrosive is not known. However, it resisted attempts
to scratch it with a sharp knife. A new file was required
to remove the very thin coating- From, this experience, it
is reasonable to expect the coating would exhibit good wear
characteristics.
The device is claimed to reduce or eliminate disc brake
drag. This in turn reduces excessive brake and tire wear
and fuel consumption. On each package (see Attachment G)
it is guaranteed that if you do not improve your fuel
economy by 10 percent, your money will be refunded-. Based
on our engineering judgment, only vehicles with severe
problems could realize a 10% improvement in fuel economy as
a result of repairs to the brake system- In general, even
vehicles with moderate brake drag would only gain a few
percent upon repair. For this reason, the applicant was
questioned (Attachment H) as to the technical basis of his
claim. He cited (Attachment B) programs with the Ohio
State Highway Patrol, United Telephone Service, and the
-------
Orange County Unified School District, as well as
testimonials from other purchasers of the device. The data
did not adequately substantiate the 10 percent claim nor
did it show that the improvements (and.their duration) were
any better than those realized when using new OEM parts.
Additionally, EPA was not satisfied with the control that
was exercised during these evaluations/testimonials and
therefore the applicant was notified of the need for new
test data which would support the claims made for the
device. The applicant subsequently notified the Agency
that he could not fund the necessary testing.
(5) The applicant states the price of the device is $34.95 and
that the average installation time for both front brakes is
a total of .7 to .8 hours. Because the device is basically
of the same design as OEM parts, EPA agrees with the
applicant that the installation cost should not differ from
that incurred when installing OEM parts. Assuming a shop
labor rate of $20 per hour, the installation cost would
amount to an additional fcl4 to $16. The price of the
device appears to fall within the wide range of prices
normally charged for OEM parts by the various domestic
manufacturers. EPA cannot determine the cost effectiveness
of the device without additional data. Not known at this
time is the difference in brake drag when equipped with the
device versus new OEM parts at the time of installation of
new parts and at some extended mileage. Another factor not
known is the average miles driven before corrosion on the
brake sliding contact surfaces cause a noticeable
difference in fuel economy. Also unknown is the
.relationship between fuel consumption and mileage when a
third variable (brake pad drag) is increasing. Yet another
unknown is the amount of tire wear that is attributable to
dragging brakes. Data on these unknowns would need to be
provided before EPA can perform a meaningful cost analysis.
Installation, Operation, Safety and Maintenance;
(1) Applicability:
The applicability of the device, as stated in Attachments A
and D, seem to be currently limited to most domestic
automobiles and trucks that have disc type brakes.
Purchasers of the device should be able to determine which
kit is applicable to their vehicle with little or no
difficulty. The applicant was asked (Attachment H) if the
device could be used on new vehicles and what model year
range the device was most effective. The applicant
responded (Attachment B) that the device could be used with
new vehicles and that the effectiveness was proportional to
the amount of brake .system deterioration. It is likely
deterioration is more a function of the conditions the
brake components are exposed to (e.g., ambient, exposure to
road salt and moisture, frequency of brake application) and
-------
the materials "used than it is to time. Any benefits of the
device are less likely to be realized in arid regions then
in other areas with high humidity/temperature or salted/wet
roads. Thus, it is possible the device may have greater
benefits for newer vehicles in some areas than for older
vehicles in other areas. Further, the benefits are limited
to disc brake designs that incorporate sliding or floating
calipers. That is, brakes which feature a piston on each
side of the rotor will not require the device because the
caliper is not intended to move in these designs. In
general, however, the applicability of the device, as
stated by the applicant,, was judged to be satisfactory.
(2) Installation - Instructions, Equipment and Skills Required;
The applicant references the installation instructions on
the reverse side of the merchandising package (Attachment
D). The instructions include step-by-step procedures which
reference a disc brake schematic which is adjacent to the
instructions. Of the ten sample kits provided to EPA, two
contained the wrong schematic.1 Aside from that problem,
the instructions were 'judged to be adequate.
EPA agrees with the applicant ,that no special tools or
equipment .are required for device installation. Hand tools
found in mechanics tool boxes are adequate for any
installation. For many installations, the hand tools
commonly- available in most homes will be sufficient.
It was also judged that average 'mechanical skills would be
sufficient for'a successful installation.
i
(3) Operation:
No specific instructions were provided for operation of a
vehicle with the device, and none were judged to be
required.
(4) Effects on Vehicle Safety:
The applicant states that the device does not differ in
design from the OEM parts and therefore, there is no
additional safety hazard than that which existed before the
installation. If the designs are identical (as they seem
to be), and the physical properties of the materials are
equivalent or superior, then the applicant's statement
would be correct. However, because the device seems
lighter than the OEM parts,, this would suggest that
different materials are being, used and therefore EPA is
concerned about the physical properties being adequate to
cope with the stresses involved. Although EPA has no other
information showing this is indeed a real problem, it is an
area which warrants further attention.
-------
EPA agrees with the applicant in that the reduction of
brake drag should lead to a reduction of brake fade and
thus, better braking capabilities. It should also improve
steering characteristics by reducing brake pull. However,
EPA does not know if the device will affect these
improvements any better than if new OEM parts were used..
5. Maintenance;
The applicant states that no maintenance is required once
the device is installed. Without durability data generated
from an appropriate test program, EPA does not know whether
the device will require more or less maintenance then that
required with OEM parts.
d. Effects on Emissions and Fuel Economy;
(1) Unregulated Emissions;
The applicant does not specifically address unregulated
exhaust emissions. However, EPA does not expect the device
to have any effect on unregulated, emissions.
(2) Regulated Emissions and Fuel Economy;
The ap'plicant did not submit test data in accordance with
the Federal Test Procedure (FTP) and the Highway Fuel
Economy Test (HFET). These two test procedures are the
primary ones recognized by EPA for evaluation of fuel
economyand emissions for light duty vehicles. The
requirement for test data following these procedures Is
stated in the policy documents that EPA sends to potential
applicants. The requirement for appropriate test data was
also explained to the applicant during a meeting. Because
most vehtc-le.s do not use disc brakes on the rear wheels and
also because only the driving wheels are in operation
during the FTP and HFET, EPA specifically asked the
applicant to develop test data using front wheel drive
vehicles. Other data which have been collected in
accordance with standardized procedures are acceptable- only
as supplemental data in EPA's preliminary evaluation of a
device. The applicant . did submit supplemental data
although it was found to be insufficient because the
control of variables during testing was not adequate.
Therefore, EPA has no data which supports the claims made
for the device.
8. Conclusions
EPA fully considered all of the information submitted by the
applicant. The evaluation of the BRAKE-EZ device was based on that
information. Appropriate data was not submitted showing the device
could achieve the benefits claimed nor did it show that the
improvements (and their duration) were any better tha-n those realized
-------
when using new OEM parts. Based on our engineering judgment, only
vehicles with severe problems could realize a 10% improvement in fuel
economy as a result of repairs to the brake system. In general, even
vehicles with moderate brake drag would only gain a few percent upon
repair. Thus, there is no technical basis for EPA to support the
claims made for the device or to perform confirmatory testing.
FOR FURTHER INFORMATION CONTACT; Merrill W. Korth, Emission Control
Technology Division, Office of Mobile Source Air Pollution Control,
Environmental Protection Agency, 2565 Plymouth Road, Ann Arbor, Michigan
48105, (313) 668-4299.
-------
List of Attachments
Attachment A EZ Line Products Catalog
Attachment B " Letter, EZ Line Products Corporation to EPA, December
21, 1981.
Attachment C EZ Line Products Installation Tips . and Service
Bulletins
Attachment D Reverse side of BRAKE-EZ merchandising products kit.
Attachment E Letter, Ohio State Highway Patrol to EPA, February 5,
1982.
Attachment F Letter, United Telephone Company of Ohio to Precision
Meta.l Craft Corporation, July 17, 1980.
Attachment G Front side of BRAKE-SZ merchandising products kit.
Attachment H Letter, EPA to EZ Line Products Corporation, December
1, 1981.
-------
EPA-AA-TEB-511-82-10B
Attachments to
EPA Evaluation of the BRAKE-EZ Device Under
Section 511 of the Motor Vehicle Information and Cost Savings Act
August, 1982
Test and Evaluation Branch
Emission Control Technology Division
Office of Mobile Sources
U.S. Environmental Protection Agency
-------
Attachment A
PAT. PEND.
PRODUCTS
MANUFACTURED BY PRECISION METALCRAFT CORPORATION
1107 East Klbtoy SL, Uma. Ohio 45804, 419f2»«7B1
-------
WE TAKE PRIDE IN THE GROWING
"ENERGY PACKAGE"
THAT EZ LINE PRODUCTS OFFERS TO YOU
* BRAKE EZ Disc Brake Parts Kit
Fits Most Domestic Autos and Trucks.
Replaces Original Equipment Parts and
Eliminates Disc Brake Drag
*CLUTCH EZ Replacement Mechanical Clutch
Linkage Kit. Contains Rod and Accessories,
Lever and Throw Out Bearing with EZ
Lube, For 6 & 8 Cyl. Chevy, Ford and GMC
Vans and Pickup Tracks. Eliminates Hard
Pedal, Clutch Chatter and Linkage Breakage.
*EZ LINE GOLD SEAL Super Lubricant Fof
Mechanical, Electrical & Electronic Uses:
Automotive, Industrial, Machine Shops,
Marine, Aircraft, Home and Farm Equipment.
MANUFACTURED BY PRECISION METALCRAFT CORPORATION
1107 East Kibby St., Lima, Ohio 45804, 419/229-5781
-------
List of Attachments
Attachment A EZ Line Products Catalog
Attachment B Letter, EZ Line Products Corporation to EPA, December
21, 1981.
Attachment C EZ Line Products Installation Tips and Service
Bulletins
Attachment D Reverse side of BRAKE-EZ merchandising products kit.
Attachment E Letter, Ohio State Highway Patrol to EPA, February 5,
1982.
Attachment F Letter, United Telephone Company of Ohio to Precision
Metal Craft Corporation, July 17, 1980.
Attachment G Front side of BRAKE-EZ merchandising products kit.
Attachment H Letter, EPA to EZ Line Products Corporation, December
1, 1981.
-------
KIT NO. 6550 FITS PIN TYPE FLOATING CAliPER DISC BRAKES
INNER BUSHING
CAUPER ANCHOR PIN
& SLEEVE
OUTER BUSHING
1 KIT FITS 2 WHEELS
The NEW BRAKE EZ DISC BRAKE PARTS KIT1 is a kit that allows the disc brake caiiper to float on the rotor therefore in-
creasing mileage performance and reducing tire wear.
... Reduces friction by a/lowing the caiiper to float on ... Increases tire life by reducing the amount of energy
the rotor instead of binding required to move the wheel
... Increases gas mileage by reducing brake drag ... Increases the disc brake pad mileage by reducing the
brake drag
WHY REINSTALL A PROVEN PROBLEM? INSTALL THE PROVEN REMEDY.
BRAKE EZ DISC BRAKE PARTS"!
Vehicle apolication is listed on reverse side.
-------
BRAKE
DISC BRAKE PARTS
FOR PIN TYPE FLOATING CALIPER DISC BRAKES
PASSENGER VEHICLES
KIT NO. 6550
1969-80 Apollo
1970-80 Centurion
1969-80 Century
1970-80 Electra
1970-80 Estate Wagon
KIT NO. 6550 ;
1968-80 Brougham
1968-80 Calais
1968-80 Commercial Sedan & Li mo
KIT NO. 6550
-BUICK-
1969-80 Gran Sport
1970-80 LeSabre
1969-80 Regal
1979-80 Riveria Fr. 4 Rr. Disc
1976-79
1969-80-
196940-
1970-80 -
Skylark
Special
Sport Wagon
Wildcat
-CADILLAC-
1968-80 DeVille
1976-80 Eldorado
196840-
1976-80-
Fleetwood
Seville
-CHECKER MOTOR.
1969-80 Checker
196940 Belair
1969-80 Biscayne
196940 Brook wood
1969-80 Camaro Except '69 Z-28
196940 Estate Wagon
1969-80 El Camino
1969-80 Custom 4 Custom Crusier
1973-80 Cutlass
1969-80 Delta 88
1969-80 Bonneville
1969-80 Catalina
1969-80 Executive
1969-80 Firebird Fr. & Rr. Disc
1969-80
1969-80
1969-80
196940
196940
1969-79 -
196940
1969-77 -
1973-79
197840
196940
196940
196940
CHEVROLET
Impala
Kingswood
Laguna
Caprice
Chevelle
Chevy II
OLDSMOBILE
Delta 98
F45
Omega
PONT1AC
Grand Am
Gran Prix
Grandviile
Lemans
1969-79
196940
196940
1969-79
196940
197140
196940
196940
1978-79
196940
196940
Concourse
Malibu
Monte Carlo
Nova
Townsman
Toronado Fr. & Rr. Disc
Vista Crusier
442
Phoenix
Safari
Ventura
TRUCKS
VANS
RECREATIONAL VEHICLES
KIT NO. 6550
197140 Blazer 2x4 4 4x4
197140 Caoallero & Sprint
C Series (Conventional)
197140 C-10 4 C-1500
197140 C-20 & C-2500
1971-73 C-30 4 C-3500
1974-80 C-30- 4 C-3500'
CHEVROLET AND CMC TRUCKS-
196940 El Camino .
197140 Jimmy C-1500
G Series (Van)
197140 G-10 4 G-1500
197140 G-20 4 G-2500
1971-73 G-30 4 G-2500
197440 G-30- 4 G-3500-
197140 Jimmy K-1500
1971-73 Motor Home
P Series (Forw»rd Control)
197140 P-10 4 P-1500
197140 P-20 & P-2500
1971-73 P-30 4 P-3500
197440 P-30- 4 P-3500'
K Series (4 Wheel Drive)
197140 K-10 4 K-1500
1971-80 K-20 4 K-2500
"Some Vehicles These Years With Sliding Caliper Or Optional Rear Disc Require Kit No. 6570
KIT NO. 6550 AMC JEEP
197440 Cherokee
197440 Gladiator
KIT NO 6570
C Series
1974-78 - C-30 4 C-3500
197S40 C-30 w/BJ4 Fr. Axle
1979-80 C-3500 w/BJ-8 Fr. Axle
K Series
1977.78 K-30
1979-80 K-30 W/EJ4 Fr. Axle
1979-80 K-3500 w/BJ-8 Fr. Axle
197440 J-20
1974-78 Motor Home
197440 Wagoneer
197440 J-10
CHEVROLET AND GMC TRUCKS
' G Series
1975-78 G-30 4 G-3500
197940 G-30 w/BJ-8 Fr. Axle
1979-80 G-3500 w/BJ4 Fr. Axle
P Series
1974-78 P-30 & P-3500
1979-80 P-30 W/BJ4 Fr. Axle
1979-80 P-30 w/1200-14500 Rr. Axle
1979-80 P-3500 w/BJ-8 Fr. Axle
197940 P-3500 w/12000-14500 Fr. Axie
Thank You For Purchasing The NEW BRAKE EZ DISC BRAKE PARTS!
Please read the following instructions carefully before installing your BRAKE EZ DISC BRAKE PARTS.
NOTE; Use Standard safety practices when working on your vehicle.
A. Jack up vehicle and remove wheel.
B. Remove the caliper pins ana remove caliper.
C. CAUTION: DO NOT HANG CALIPER ON BRAKE LINE.
D. After removing caliper remove old caliper sleeves and bushings. Make sure ALL RUST is removed from slide areas of the caliper and anchor plate (use the
encloseo scrubber pad). IMPORTANT: In some cases a file must be used to remove rust before using enclosed scrubber pad.
E. Install the new caliper bushings provided then apply EZ LUBE (furnished in the enclosed tube) to inside surfaces of the caliper bushings and onto the same
slioe areas cleaned in step "D".
r. Install NEW sleeves provided.
3. Reinstall calioer into anchor frame and install NEW caliper pins. Torque to spec. (15-18 ft. Lbs.)
H. Reinstall wheel (toraue lug nuts to spec.) remove jack. .
!. CAUTION: DO NOT MOVE VEHICLE UNTIL FIRM PEDAL IS ACHIEVED.
J. if disc Drakes do not release. REPLACE PISTON SEALS IN CALIPERS.
-------
SLIDING CALIPER
BRAKES
EZLUBE
SURFACES A-8-C-0
RETAINER SCREWS
1 KIT FITS 2 WHEELS
The NEW BRAKE EZ DISC BRAKE PARTS KIT' is a kit that allows the disc brake.calipeno 1ioat on the rotor therefore in-
creasing mileage performance and reducing tire wear.
... Reduces friction by allowing the caliper to float on ... Increases tire life by reducing the amount of energy
»»._ »~. ;.- « u;_^;nn required to move the wheel
the rotor instead of binding
... Increases gas mileage by reducing brake drag
... Increases the disc brake pad mileage by reducing the
brake drag . .
WHY REINSTALL A PROVEN PROBLEM? INSTALL THE PROVEN REMEDY.
BRAKE E2 DISC BRAKE PARTS'!
Vehicle application is listed on reverse side.
-------
BRAKE 55'
DISC BRAKE PARTS
FOR RETAINING CLIP TYPE SLIDING CALIPER DISC BRAKES
PASSENGER VEHICLES
M 1 r»U. 031U
1976-80
1974-.75'
1974-78
1980
1975 '-SO -
1974-
1973-76
1977-80
1974
Aspen
Charger
Chrysler
Chrysler LS
CoraoDa
Coronet
Dart
Diplomat
Dodge
CHRYSLER Single Piston Slider Type-
1975-77 Gran Fury
1980 Gran Fury
1974-75 Imperial
1974-75 Imperial opt. Rr. Disc
1977-80 LeBaron
1979 Magnum XE
1980 Mirada
1975-76 Monaco
1974 & 80 Newport
'Some Vehicle Applications This Year Have Pin Type Brakes Requiring Kit No. 6525
1974 & 80 New Yorker
1974 Plymouth
1974-76 Polara
1977 Royal Monaco
1974* Satellite
1974 Town & Country
1979-80 St. Regis
1973-76 Valiant
1976-80 Volare
TRUCKS
VANS
RECREATIONAL VEHICLES
KIT NO. 6510-
1974-80
1974-80
1973-80
1973-80
197E
1978
1974-80
Ramcnarger . 2-WD & 4-WD
Trailduster 2-WD & 4-WD
B 100 Voyager & Traoesman
D 100 Conventional CaD 4x2
B 150 Voyager & Tradesman
D 150 Conventional CaD 4x2
W 100 Conventional CaD 4-WD
w/Spicer 44 BJ Axle
-CHRYSLER Light Trucks and Motor Homes-
1973-80 B 200 Voyager & iradesman
1973-80 D 200 Conventional CaD
197
-------
KIT NO. 6525 FITS PIN TYPE FLOATING CAliPER DISC BRAKES
INNER BUSHIN
CAUPER ANCHOR PIN
OUTER BUSHING
ANCHOR PLATE
1 KIT FITS 2 WHEELS
The NEW BRAKE E2 DISC BRAKE PARTS KIT* is a kit that allows the disc brake caliper to float on the rotor therefore
increasing mileage performance and reducing tire wear.
... Reduces friction by allowing the caliper to float on ... Increases tire life by reducing the amount of energy
the rotor instead of binding required to move the wheel
. .. Increases gas mileage by reducing brake drag ... Increases the disc brake pad mileage by reducing the
brake drag
WHY REINSTALL A PROVEN PROBLEM? INSTALL THE PROVEN REMEDY.
BRAKE E2 DISC BRAKE PARTS'!
Vehicle aoplication is listed on reverse side.
-------
BRAKE
DISC BRAKE PARTS
FOR PIN TYPE FLOATING CALIPER DISC BRAKES
PASSENGER VEHICLES
KIT NO. 6525-
1974 Barracuda
1974 Belvedere
1974 Challenger
1974- & 75 Charger
'Some Vehicle Applications This Year Have Slider Type Brakes Requiring Kit No. 6510
CHRYSLER Single Piston Pin Type
1976-78 Charger 1975-78
1976-78 - Charger SE 1975-78
1975* Cordoba 1977
1976-78 Cordoba 1974'
Coronet
Fury
Monaco
Satellite
OTHER CHRYSLER BRAKE EZ DISC BRAKE PARTS KITS AVAILABLE
CHRYSLER Single Piston Pin Type
1978-80 Omni
1978-80
1976-80 -
1974--75'
1974-78
1980
1975--80 -
1974-
1973-76 -
1977-80
1974
Horizon
(
Asoen
Charger
Chrysler
Chrysler LS
Cordoba
Coronet
Dan
Diplomat
Dodge
CHRYSLER Single Piston Slider Type
1975-77 Gran Fury
1980 Gran Fury
1974-75 Imperial
1974-75 Imperial opt. Rr. Disc
1977-80 LeBaron
1979 Magnum XE
1980 Mirada __
1975-76 Monaco
1974 & 80 Newport
'Some Vehicle Applications This Year Have Pin Type Brakes Requiring Kit No. 6525
1974 & 80 New YorXer
1974 Plymouth
1974-76 Polara
1977 Royal Monaco
1974- Satellite
1974 Town & Country
1979-80 St. Regis
1973-76 Valiant
1976-80 Volare
TRUCKS
KIT NO. 6510-
1974-80
1974-80
1973-80 .
1973-80
1978
1978
1974-80
KIT NO. 6422
1974-79
KIT NO. 6520
1979-60
1974-80
VANS
CHRYSLER -
RECREATIONAL VEHICLES
Ramcharger 2-WD & 4-WD 1973-80
TrailOuster 2-WD & 4-WD 1973-80
B 100 Voyager &. Tradesman 1974-80
D 100 Conventional Cab 4x2
B 150 Voyager & Tradesman 1978-80
D 150 Conventional CaD 4x2 1S73-80
W 100 Conventional Cab 4-WD 1973-80
w/Soicer 44 BJ Axle
Light Trucks and Motor Homes -
B 200 Voyager & Tradesman 1973-80
D 200 Conventional Cab 1973-80
W 200 Conventional Cab 4-WD 1973
w/Spicer 44 BJ Axle 1973
RD 200 Conventional Cab RV 1976-80
B 300 Voyager 5. Tradesman 1976-80
D 300 Conventional Cab
CB 300 Compact Fr. Section Only
MB 300 Compact Fr. Section Only
M 300 Motor Home
3 400 Voyager & Tradesman
CB 400 Compact Fr. Section Only
MB 400 Compact Fr. Section Onlv
4-WD Conventional Cab W-200-300-400 w/Spicer 60 Axle
CHRYSLER Dual Piston Slider Type
M 300 Motor Home 1974-80 M 500 Motor Home 1974-77
M 400 Motor Home 1974-80 M 600 Motor Home 1974-77
R 400 Recreational
R 500 Recreational
Thank You For Purchasing
The NEW BRAKE EZ DISC BRAKE PARTS KIT!
Please read the following instructions carefully before installing your BRAKE EZ DISC BRAKE PARTS KIT.
NOTE: Use Standard safety practices when working on your vehicle.
A. Jack up vehicle and remove wheel.
Remove the caiiper pins and remove caliper.
CAUTION: DO NOT HANG CALIPER ON BRAKE LINE.
After removing caliper remove old bushings. Make sure ALL RUST is removed from slide areas of the caliper and anchor
plate. IMPORTANT: In some cases a file must be used to remove rust before using enclosed scrubber pad.
E. Install the new caliper bushings provided then apply EZ LUBE (furnished in the enclosed tube) to inside surfaces of the
caliper bushings and onto the same slide areas cleaned in step "D".
F. Reinstall caliper into anchor frame and install NEW caliper pins. Torque to spec. (15-18 ft. Lbs.)
G. Reinstall wheel (torque lug nuts-to spec.) remove jack.
H. CAUTION: DO NOT MOVE VEHICLE UNTIL FIRM PEDAL IS ACHIEVED.-
I. If disc brakes do not release, REPLACE PISTON SEALS IN CALIPERS.
£2520-1/14/81 Congratulations! You have just installed America's newest concept in energy efficiency.
B.
C.
D.
MANUFACTURED BY PRECISION METALCRAFT CORPORATION
1107 East Kibby St.. Lima. Ohio 4530^. -119/229-5781
-------
tt£g&ft£aC£jj
1 i" AaZT-.H*
KIT NO. 6422-6475-6570 FITS SLIDING CALIPER DISC BRAKES
ANCHOR PLATE
-»6Z LUBE
CALIPER
ASSEMBLY
OUTER BRAKE SHOE
& LINING ASSEMBLY
EZ LUBE,.
RETAINER KEY
& SCREW
1 KIT FITS 2 WHEELS
The NEW BRAKE EZ DISC BRAKE PARTS KIT* is a kit that allows the disc brake caiiper to float on the rotor therefore in-
creasing mileage performance and reducing tire wear.
... Reduces friction by allowing the caiiper to float on ... Increases tire life by reducing the amount of energy
the rotor instead of binding required to move the wheel
... Increases gas mileage by reducing brake drag ... Increases the disc brake pad mileage by reducing the
brake drag
WHY REINSTALL A PROVEN PROBLEM? INSTALL THE PROVEN REMEDY.
BRAKE EZ DISC BRAKE PARTS"!
Vehicle application is listed on reverse side.
-------
BRAKE S~
DISC BRAKE PARTS
FOR KEY TYPE SLIDING CALIPER DISC BRAKES
PASSENGER VEHICLES
1975-80 Concord
1975-78 Gremlin
1975-77 Hornet
972-77 Cobra
1973-77 Country Sedan Fr. & Rr. Disc
1573-77 Country Souire Fr. & Rr. Disc
1972-77 Elite
1972-77 Fairlane
1973-77 Ford Custom Fr. & Rr. Disc
KIT NO 6d22 » -
1974-80 Bobcat
1973-78 Colony ParK Fr. & Rr. Disc
1974-77 Come;
"973-79 Commuter Fr. & Rr. Disc
",974-79 Cougar
,974.79 _ XR7
1974-79 Eliminator
1972-76 Cyclone
TRUCKS
1974-79 4 Wheel Drive Conventional CaD W
KIT NO fid?9
1975-78 Matador
1975-80 - Pacer
1979-80 Spirit
FORD
1976-77 Ford Galaxie Fr. & Rr. Disc
1973-77 Ford LTD Fr. Disc
1976-79 Ford LTD II Fr. & Rr. Disc
1972-77 Gran Torino
1974-80 Granada Fr. & Rr. Disc
1974-77 Maverick Fr. & Rr. Disc
i IN^DLN MERCURY
1977-80 CJ5 - CJ6 CJ7
1974-78 Mustang
1974-80 Pinto
1972-77 Ranch Wagon
1972-79 Thunderbird Fr. & Rr. Disc
1972-77 Torino
1973-78 Gran Marauis Fr. & Rr. Disc 1973-78 Montclair Fr. & Rr. Disc
1973-79 Lincoln Fr. & Rr. Disc 1972-76 Montego. MX & Spoiler
1973-78 Marauder Fr. & Rr. Disc 1973-78 Monterey Fr. & Rr. Disc
1972-79 MarK IV & V Fr. & Rr. Disc 1973-78 Park Lane Fr. & Rr. DISC
1973-78 Marrjuis Fr. & Rr. Disc 1978-80 Versailles
1973-78 Mercury Fr. & Rr. Disc 1974 _ Villager
1974-80 Monarch Fr. & Rr. Disc 1974 _ Voyager
VANS RECREATIONAL VEHICLES
CHRYLSER CORP
200-300-400 With Spicer 60 Axle
, FORD TRUCK
1976-80 Bronco
1972-79 Rancnero
KIT NO. 6422
1974-80 Conventional
1S74.75 Moael 100 & 150
KIT NO. 6475
i°76-80 All E a r Series 250 Heavy Duty
KIT NO. 6570
C Series
1974-78 C-30 i C-3500
1979-80 - C-30 w/EJ-8 Fr. Axle
1979-60 C-3500 w/BJ-6 Fr. Axle
K Series
1977-78 K-30
1979-80 - K-30 w/BJ-8 Fr. Axle
1979-80 K-3500 w/BJ-8 Fr. Axle
1974-78 Moior Home
1973-80 E-100 & E-150(V: Ton)
1973-80 E-250 Series ->* Ton.w/Single Piston
INTERNATIONAL HARVESTER-
1974-80 Scout
1974-80 Travelall 1.000
FORD TRUCK DUAL PISTON
1976-80 - All E & F Series 350
CHEVROLET AND CMC TRUCKS-
1973-80 F-100 & F-150 PicKuo Truck
1974-76 200 =/« Ton w/Std. From Axle
G Series
1975-78 G-30 & G-3500
1979-80 G-30 w/BJ-8 Fr. Axle
1979-80 G-3500 w/BJ-6 Fr. Axle
P "Series
1974-78 - P-30 & P-3500
1979-80 P-30 w/BJ-8 Fr. Axle
1979-80 P-30 w/1200-14500 Rr. Axle
1979-80 P-3500 w/BJ-8 Fr. Axle
1979-80 P-3500 w/12000-14500 rr. Axle
Thank You For Purchasing
The NEW BRAKE EZ DISC BRAKE PARTS!
Please read the following instructions carefully before installing your BRAKE EZ DISC BRAKE PARTS.
NOTE: Use Standard safely practices when working on your vehicle.
A. Jack up vehicle and remove wheel.
3. Remove retaining bolt. OLD key and spring as illustrated on front page.
C. CAUTION: DO NOT HANG CALIPER ON BRAKE LINE.
D. Remove caliper. NOTE: ALL RUST must be removed from slide areas of the caliper and anchor plate (use the enclosed
scrubber pad). Then apply the EZ LUBE furnished in the enclosed tube to these same slide areas and on retainer KEY and
SPRING as noted on front page. IMPORTANT: In some cases a file must be used to remove rust before using enclosed
scrubber pad.
E. Reinstall the caliper.
=. Insert KEY and SPRING in original position. NOTE: Make sure KEY SLOT is in alignment with BOLT HOLE before installing
BOLT (15 ft.-Ibs. toraue).
3. Reinstall wheel (torque lua nuts to spec.) remove jack.
-;. CAUTION: DO NOT MOVE~VEHICLE UNTIL FIRM PEDAL IS ACHIEVED.
'. If disc brakes do not release. REPLACE PISTON SEALS IN CALIPERS.
-;:-.- ?>;- " Congratulations! You have just installed America's newest concept in energy efficiency.
MANUFACTURED 3Y PRECISION M'TALCrAFT C
-------
D
LrklA:
j» ! SI
KIT NO. 6480-6490 FITS PIN TYPE FLOATING CALJPER DISC BRAKES
_*EZ LUBE,
CAUPEH
RUBBER INSULATOR
SLEEVE
L CALIPER GUIDE PIN
1 KIT FITS 2 WHEELS
The .NEW BRAKE EZ DISC BRAKE PARTS KIT* is a kit that allows the disc brake caliper to float on the rotor therefore in-
creasing mileage performance and reducing tire wear.
... Reduces friction by allowing the caliper to float on ... Increases tire life by reducing the amount of energy
the rotor instead of binding required to move the wheel
. .. Increases the disc brake pad mileage by reducing the
brake drag
WHY REINSTALL A PROVEN PROBLEM? INSTALL THE PROVEN REMEDY.
BRAKE £2 DISC 8RAKE PARTS*'.
Vehicle application is listed on reverse side.
.. Increases gas mileage by reducing brake drag
-------
BRAKE
DISC BRAKE PARTS
FOR PIN TYPE FLOATING CALIPER DISC BRAKES
PASSENGER VEHICLES
KIT NO. 6480
1978-80 Fairmont
FORD
KIT NO. 6480
1978-80 Capri
1978-80 Mustang
LINCOLN MERCURY-
1980 Thundertoird
1980 Cougar
1978-80 Zephyr
KIT NO. 6490
1979-80 LTD
FORD-
KIT NO. 6490
1980 Continental
1979-80 Country Squire
LINCOLN MERCURY-
1980 Mark VI
1979-80 Marquis
OTHER FORD BRAKE EZ HARDWARE KITS AVAILABLE
PASSENGER VEHICLES
tf IT Ufl
M \ nu.
1972-77
1973-77
1973-77
1972-77
1972-77
1973-77
^tT kjr^
KIT NO.
1974-80
1973-78
1974-77
1973-79
1974-79
1974-79
1974-79
1972-76
** *nm
Cobra
Country Sedan Fr. & Rr. Disc
Country Squire Fr. & Rr. Disc
Elite
Fairlane
Ford Custom Fr. & Rr. Disc
f Mf**l
Bobcat
Colony Park Fr. & Rr. Disc
Comet
Commuter Fr. & Rr Disc
Cougar
XR7
Eliminator
Cyclone
1976-77
1973-77
1976-79
'1972-77
1974-80
1974-77
1973-78
1973-79
1973-78
1972-79
1973-78
1973-78 -
1974-80
FORD
Ford Galaxie Fr. & Rr. Disc
Fora LTD Fr. Disc
Ford LTD II Fr. & Rr Disc
Gran Torino
Granada Fr. & Rr. Disc
Maverick Fr. 4 Rr. Disc
LINCOLN MERCURY
Gran Marquis Fr. 4 Rr. Disc
Lincoln Fr. & Rr. Disc
Marauder Fr. & Rr. Disc
Mark IV & V Fr. & Rr. Disc
Marquis Fr. & Rr. Disc
Mercury Fr. & Rr. Disc
Monarch Fr. & Rr. Disc
1974-78
1974-80
1972-77
1972-79
1972-77
1973-78
1972-76
1973-78 -
1973-78
1978-80
1974
1974
Mustang
Pinto
Ranch Wagon
Thundernird
Torino
Montciair Fr.
Montego MX
Monterey Fr.
Park Lane Fr
Versailles
Villager
Voyager
Fr. & Rr. Disc
& Rr. Disc
& Spoiler
& Rr. Disc
. & Rr. Disc
TRUCKS
VANS
RECREATIONAL VEHICLES
KITNO.M22
1976-80 Bronco
1972-79 Ranchero
FORD TRUCK-
KIT NO. 6475
1976-80 All E & F Series 250 Heavy Duty
1973-80 E-100 &. E-15u.(V2 Ton)
1973-80 E-250 Series V« Ton
w/Single Piston
FORD TRUCK DUAL PISTON-
1976-80 All E & F Series 350
1973-80 F-100 & F-150 Pickup Truck
Thank You For Purchasing The NEW BRAKE EZ DISC BRAKE PARTS!
Please read the following instructions carefully before installing your BRAKE EZ DISC BRAKE PARTS.
NOTE: Use Standard safety practices when working on your vehicle.
A. Jack up vehicle and remove wheel.
B. Remove caliper pins and remove caliper.
C. CAUTION: DO NOT HANG CALIPER ON BRAKE LINE.
D. After removing caliper, remove old plastic sleeves and rubber insulators. Make sure ALL RUST is removed from slide areas
of the caliper and anchor plate (use the enclosed scrubber pad). IMPORTANT: In some cases a file must be used to remove
rust before using enclosed scrubber pad.
E. Push the metal sleeves approximately Vi" to Vz" into the rubber insulators. Push the rubber insulator into caliper with a
1/4" diameter bolt or punch approximately 5" long. CAUTION. DO NOT USE A SHARP OBJECT. IT WILL DAMAGE THESE
PARTS. After the rubber insulator is pushed into the original position, push the remainder of the metal sleeve into it, mak-
ing sure the sleeve is behind the seal lip of the insulator.
F. Apply EZ LUBE (furnished in the enclosed tube) into the sleeve and onto the same slide areas cleaned in Step "D".
G. Reinstall caliper into anchor frame and install caliper pins. Torque to spec. (15-18 Lbs.).
H. Reinstall wheel (torque lug nuts to spec.) remove jack.
I. CAUTION: DO NOT MOVE VEHICLE UNTIL FIRM PEDAL IS ACHIEVED.
J. If disc brakes do not release, REPLACE PISTON SEALS IN CALIPERS.
=Z7oi-i;7/8i Congratulations! You have just installed America's newest concept in energy efficiency.
MANUFACTURED BY PRECISION METALCRAFT CORPORATION
-------
Attachment B
j < ' I
J J -A -W Js/ .W --^ J
P.O. Box 05, Umo. Ohio 45802 - 4 19/229-5781
Manufactured by Precision Mefo'cro^f Corporofion
December 21, 1981
EPA
Motor Vehicle Emission Laboratory
2565 Plymouth Road
Ann Arbor, MI 48105
Attention: Mr. Merrill W. Korth
Device Evaluation Coordinator
Dear Mr. Korth-:
We have reviewed the comments and requests for additional information
by your Engineering Evaluation Group.
The enclosed information should clarify the principles of operation
and the fuel savings related to the use of BRAKE EZ.
If you should have any further questions please contact me.
MAY YOUR HOLIDAYS BE JOYFUL AND YOUR NEW YEAR PROSPEROUS.
Sincerely,.
EZ LINE PRODUCTS CORPORATION
Robert W. LaWarre -II
Vice President
Research and Development
I RWL/bl
i
! Enc.
-------
December 21, 1981
First, let us review the operation of a single piston, sliding caliper disc
brake which-is commonly found on today's passenger car and light truck.
Upon brake application, fluid pressure against the piston forces the
inboard brake pad against the inboard surface of the rotor. This action
causes the caliper to slide until the outboard brake pad comes in contact
with the outboard rotor surface.
It is largely assumed that "zero" clearance between the brake pads and
the rotor is a prerequisite for proper operation of all disc brake systems,
The theory is that excessive brake pedal travel is incurred if the brake
pads are not in contact with the rotor surfaces. This is not the case
with the single piston sliding caliper type disc brake system where the
piston seal acts to retract the piston .020 - .030 inch after the fluid
pressure is released. This system is designed with adequate master
cylinder fluid displacement and minimal brake pedal "free play" to over-
come the caliper piston retract. This retract of the piston allows
"running clearance" between the inboard rotor surface and the inboard
brake pad, but, the resistance to the sliding motion of the caliper
on its slide does not allow the caliper to slide outward. Consequently,
the outboard brake pad has a residual- pressure against the outside rotor
surface. This residual pressure (i.e. brake drag) is directly proportional
to the resistance to the movement of the caliper on its slide. This
resistance is, in turn, directly related to the amount of exposure of the
braking system to the elements which deteriorate the calipers and mounting
hardware through rust and corrosion, i.e. rust and corrosion of the caliper
slide surfaces and caliper mounting hardware causes a binding of the caliper
on its slide. During braking, this increased resistance to the sliding
motion is overcome by the fluid pressure on the piston.
-------
jecemoer ^ i, i98l - Page 2. .
However, the greater the resistance to the sliding motion of the caliper
on its slide the greater the.residual pressure of the outboard brake pad
on the rotor. This relates to greater brake drag, shortened brake pad
life, excessive heat buildup in brake components, tire wear and increased
fuel consumption.
BRAKE El reduces the resistance to the sliding motion of the caliper on
its slide. It, in effect, allows the caliper to "find its own center"
over the rotor. Sufficient resistance is required to assure that piston
"knock-back" does not occur, although excessive resistance will cause
drag. Through the use of new technology in materials, material coating
processes and lubricants, a uniform amount of resistance is maintained
throughout the life of the brake pads.
In direct answer to your questions:
1. BRAKE EZ was developed during a-study of United Telephone
Service vehicles to determine the cause of premature brake
pad wear and rotor loss. The eighteen month study began in
November, 1978, and encompassed twenty-one vehicles. The
results, of this study, are stated in a July 17, 1980, letter
to Precision Metalcraft Corporation from United Telephone Service,
We have based our claims on a current five-vehicle program with
the Ohio State Highway Patrol, results from the United Telephone
Service study, reports from the Orange County Unified School
District in Orange County, California, and'numerous reports of
mileage increases from customers having the device installed on
their personal cars.
-------
December 21, 1981-Page 3. . '
BRAKE £Z has been in the market place since June, 1980. Twelve
Thousand kits were sold and installed in its first year. Many
of these customers have purchased kits for their second or third
vehicle.
2. BRAKE EZ has had excellent results with the make and model years
up through and including T980. Results are slightly higher in
earlier models due to the severe deterioration discussed earlier.
The results encountered in newer vehicles show the same de-
terioration occuring and mileage gains are proportional to the
amount of deterioration.
BRAKE EZ can be used on new cars and we are presently working
'with a major car manufacturer to determine the positive effects
on new car mileage and brake pad life in relation to service
warranty. - -
3. The effects of BRAKE EZ on vehicle operation include lower rotor
temperatures, less rolling resistance and longer brake 'pad life.
There is no affect on pedal free play or the capacity requirements
of the master cylinder.
4. In all applications, BRAKE EZ replaces existing O.E.M. parts in
the brake assembly. These O.E.M. parts are subject to rust,
corrosion and wear. Generally O.E.M. parts are reinstalled
without replacement and until BRAKE EZ, there was little aware-
ness of the fuel waste' associated with the deterioration of the
braking system. Our recommendation is to replace our parts if
they show signs of wear or if they are damaged. Typically,
our parts have been reused during the installation of new brake
pads.
-------
Trie' suggested list price is S34.95 on'all BRAKE EZ Kits
presently in production. The average installation time is
.7 - .8 hours. However, when installed during brake pad
installation, no additional labor should be charged. The
suggested list price compares to a high of $44.00 for General
Motors O.E.M. parts and a low of $15.00 for Ford O.E.M.
replacement parts.
The kits are marketed through the normal automotive aftermarket
channels and national merchandisers-automotive service centers.
-------
Attachment C
UNE
PRODUCTS
P.O. Bex 35. Uma. OMo 45803 4I9/239..S78I
Moou/ortufW by fVccfeJon M«rokrwrt Corporation
BRAKE EZ SERVICE BULLETIN
RE: KIT »6570 - SENERAL MOTORS 3000 THRU 3500 SERIES CHASSIS
Caliper Rattle - Some medium duty truck and motor home applications
have an excessive accumulation of machining tolerances between the
caliper and anchor plate slide areas. This excessive tolerance
buildup reduces the effective spring preload and allows the caliper
to rattle in the anchor plate. To detect this condition the follow
ing procedure is recommended:
1. Thoroughly clean all slide surfaces of caliper and
anchor plate.
2. Apply lube to these same areas and install key and
spring per kit instructions..
: 3. Check the clearance-between the caliper and curb of
the key with a feeler "§age as shown on illustration. '
This clearance shouTd jie-.Q2Q-.030 inch. Lf the
clearance is in excess'of .030, remove spring and
key assembly and install shim as shown in illustration.
Reinstall spring and key and recheck for proper
clearance.
If there are any questions concerning .this bulletin, please feel
free to call me at (419)223-1751.
Robert W. LaWarre II
Research and Development
9/81
IHVOAIO
tOtOi
tf* 6570-J .028 I«H
P/» 6570-4 .015 iHOt SJIH
.020-.030 INCH
CUARAMX
1HIIV.O
-------
PRODUCTS
P.O. BOM 35. Lima. OMo 45*02 419/239-5781
Monwfoc*ur»4 bj Pndtioa Mvtofcroft Corporation
BRAKE EZ SERVICE BULLETIN
KIT #6550 - GENERAL MOTORS VEHICLES
A small percentage of General Motors light truck applications have
anchor pin mounting holes that are off location. This condition
forces the caliper to bind against the anchor plate buttress at
one end and does not allow the caliper to float. This condition
can be readily determined by observing the clearance between the
anchor pin sleeve and the caliper bushing hole. In an extreme
case, the anchor pin sleeve will_rub the caliper bushing hole. The
solution to this problem is~ ta machine the buttress contact face of
either the caliper or the anchor. Ideally, a .005 inch feeler gage
should slide between the caliper.-^nd anchor buttress at both ends.
If there are any questions concerning this bulletin, please feel
free to.call me at (419)223-1751.
Robert W. LaWarre II
Research and Development
9/81
-------
B PRODUCTS
**' "B*X P.O. So* 35. Umo. Ohio 45802 - 419/229-578?
Monvfocfurvd by PrvcfeJon AUtefaroft
BRAKE EZ INSTALLATION TIPS
DURING INSTALLATION:
1. Check wheel bearings (repack if necessary) and retorque to
3-5 INCH POUNDS. Do not over tighten.
2* Check pad backers on used pads for damage or looseness. Bend
retainer lugs on outer pad to retain pad on caliper. A loose
outer pad will rattle and cause brake squeal.
AFTER INSTALLATION:
1. Check master cylinder fluid level.
Make sure the rubber boot in master cylinder lid is in
the collapsed position. If it is extended, it will
pressurize the fluid to the caliper and the pistons
will not retract properjy.
2. Check caliper piston for proper retract. ,
Pistons sometimes-hang up causing severe drag. This
problem is severe with plastic pistons in late Chrysler
and Ford models. The-^iston should retract .01 5-. 020
minimum after brake* peda-1 is depressed and. released.
Rebuild the caliper when piston does not-function
properly.'
3. Check the freedom of caliper movement on its anchor plate
or anchor pins.
The caliper should slide from side to side. A small
amount of resistance to sliding motion is normal. If
a small amount of side to side movement is not present
after a firm brake pedal is established, recheck for
caliper piston retract.
Any further questions, please feel free to call me at (419)223-1751.
Robert W. LaWarre II
Research and Development
9/81
-------
Attachment D
MT NO. 5550 PITS PIN TYPE FLOATING CALIPES DISC BRAKES
BRAKE ~5
1 KIT FITS ? WHEELS
DISC BRAKE PARTS
Thank You For Purchasing
The NEW BRAKE EZ DISC BRAKE PARTS.'
B«*KE EZ DISC BAAKE
MOTE: UM &Unowa salvty pr»cuc*» IB
A. Jack up v«fttci* ano f
» ca*tD*r.
C. CAUTION: OO NOT HANG CAUPEROM BRAKE
0. Aha* f»mo*«ftg caMo* r>mo»» 0*0 eafepw si***** a
«**» ALL RUST t» f»nx>»«o Irem W*o* ar*as of in* cabotr ana ancnar
plat* IUM mt nctOMd acrucoa* oacft.
E. tnstaulh*n*wcaMO*rOusA*nQftp^RMOMim«napo>rEZLU8£tK«m*«A«(I
in m* ncJOMd tub*) » m»io« auftaca* of tfi* catio*'' bwatkngs ana onto
in st*o "O~.
F. Inmtalt NVK »IM«O« pre«K)Ml.
G. Rvinstall callD*r mio »ncftor tramcandiAfttall NEWca*fpartHn«. Tortn**
to »p»c, (IMS n. LDil
H. Awnstail *»/»< (lorou* *u<3 nuts lo tD*c.) * rwrov* tacK.
i. CAUTION: oo NOT WOVE VEHICLE UNTIL Pt«w PEDAL >s ACHIEVED.
J. II oisc bfa-rs oo r«oi '*»». REPLACE PISTON SEALS IN CALIPERS.
VEHICLE APPLICATION LISTS
PASSENGER VEHICLES
BUICX
1WS-AO - G'»A Soon
KIT NO. tUB-
CADILLAC .
FIT NO. Mi* -
icrr NO. MM -
MOTOR
I96940 ucvt»C
19»79 - No.<
. OLDSMOBILE
19W-M - Ov
KIT WO. «»-
. PONTIAC .
- (rrtKXMsa
TRUCKS
197140 - o>u*
VANS RECREATIONAL VEHICLES
- CHEVROLET AND CMC TRUCKS :
-»* (* W»MM
*-lO i K.iXX)
VBO *-?0* K-350D
197\-«0 &-IO A G-iiOO
<97l «0 C-» * C-2MO
1971- D G-M 4 C-lbOO
19?*-*0 C-30* 4 C-OWO'
l^ri^o P-K> & P-7500
!9fv73 - H3i-P3bCC
.W.-BO- f » k ^5500-
AMC JEEP
. CHEVROLET AND CMC TRUCKS
1979-BO C-X *<&J-« f-' A.I*
197* 80 C-3bOO flJ-8 Ff *.»*
1977.78 *-X
t97S-7» C-DO i C-3MO
1970^0 G-DO SJ^ f r
I979-«0 C-liOO *-aj-A P
Q~ 120000000 F
E2501-1/7/81
MANUFACTURED SY PRECISION METALCPAFT CORPORATION
1107 EAST KtBBY, LIMA, OHIO -45S04, 419/229-5781
^^^VWS^^K^j^^^^&SV^^^^s^vSi
' ' ---.- ^;.r:t^^>^.^-t₯4^!W»^Ji1?^.&;:-B^J?^»^*>A'*i..
.r - -..-. 'v.^-vr/r..^^^.;^.;?^?^-?:;^-^--:"^-"-^:'-
. ' ' i.j;:/^-S;^v.-:r,^.%Ui.-^'.-->-::.---
-------
COLONEL JACK. WALSH
Suocrintendorrt
Attachment E
FILE NO. 00-3-35
Columbus, Ohio 43205
February 5, 1982
Mr. Merrill W. Korth
Device Evaluation Coordinator
Test and Evaluation Branch
U. S. Environmental Protection Agency
Ann'Arbor, Michigan 48105
Dear Mr. Korth:
In response to your correspondence-of January 26, 1982, the Ohio
State Highway Patrol is in the process of evaluating the Brake E-Z
product to which you refer.
We installed two units on 1980 Plymouths in February, 1981, and
based on preliminary analysis expanded that.test to three more
1980 Plymouths in May, 1981.
m
When we compare these cars to their own record before installation
of the Brake E-Z kits, they show an average of 8.24 percent
improvement in miles per gallon. Within the average,we had one
car show a decrease of 27 MPG, and the best increase being shown by
one car of 1.53 MPG improvement.
On the other hand, when we compare these cars to other cars of the
same make and model, we find that the average miles per gallon
improvement was only .59 percent, or 6/10ths, which.is considerably
lower than the comparison shown above.
It should be pointed out that we have established several other
programs during this time period, which have also affected our
MPG average's, thus the percentages shown above may not be entirely
due to the Brake E-Z product.
We have established an ongoing driver efficiency training program
and installed an on-board computer in a car at each post to monitor
the results.
-------
Mr.. »Merrill W.' Korth '
Page 2 '
We have also established an. automated car file within our computer
system, which allows the intermediate supervisors to -monitor and
correct any problems with vehicles, or driving habits, before they
effect the post, district, or state averages.
Preliminary analysis of the evaluation of Brake . E-Z prompts us to
expand our evaluations to other areas of the state.
We hope this information will, be useful to you, and it should be
clear that the Ohio State Highway Patrol, does not endorse this, or
any other product.
truly yours ,
Colonel-fack Walsh
Superintendent
-------
. Attachment F
UM1THD TE5-EPHC3ME COMPAiMY CF OHIO
122 SOUTH ELIZABETH STREET P.O. BOX 2001 LIMA. OH»O 45801 PHONE (419) 228-1200
July 17, 1980
Precision Metalcraft Corporation
P. 0. Box 35
Lima, Ohio 45802
ATTENTION: Mr. Robert W. LaWarre, Sr.
President
Dear Bob:
I am writing you in reference to your new BRAKE EZ KIT that
we have installed in our company vehicles.
First, let-me say your BRAKE EZ KIT is just fantastic. It has
even perfoj^ped beyond our expectations.
We, at United Telephone Company, have confirmed, through our
computer data that the BRAKE EZ KIT has consistently improved
our vehicles mileage by 20 to 30 percent during the past few
months.
Bob, you might also like to know, the life of these vehicle disc
brakes was formerly between 8,000 and 10,.000 miles. Since the
installation of your BRAKE EZ KIT, brake life has been stretched
up to 40,000 miles. The BRAKE EZ KIT also reduces premature
tire wear.
Your BRAKE EZ KIT has resulted in a substantial savings in fuel,
brake lining and tires.
We, at United Telephone Company, would like to thank you and your
organization, in this endeavor.
Sincerely yours
UNITED TELEPHONE COMPANY
OF OHIO
, Urban Thaman
UT/dlf
-------
Attachment G
' BfiAKE S MONET BACK GUARANTEE - 1 0% mileage increase or your
money bacK. It not completely satisfied, return prepaid. with proof ot pur-
- erase within 90 days, lor purchase price refund to: E2 Une Products,
P.O. Box 35, Uma..OH 45802. Installation, taxes, and shipping charges1
'__:, excluded. Installation must be in accordance with Instructions provided.
r-v^^^"^^?"^*^ *"i*t^w*»fr -J1i-m±£.' - J>l ^ . - - - IT' T. I" - ' .,-JjLy. ^'ff":'^«^J^.^V -T^j^f - > *fl^|
«jyS^^^6jl/^J^^ife^^Ss^£*r^^^^t^g^|^^
jse^^gepf^^^^^iP^ag^igB^^^
^^ A«i-^r
«j^^S^»
^'XA&P'-^
S^^
-------
ATTACHMENT H
December 1, 1981
Mr. Robert W. LaWarre, II, Vice President
EZ Line Products
P.O. Box 35
Lima, OH 45802
Dear Mr. LaWarre:
I have received your letter of November 10 in which you applied for an
EPA evaluation of the "Brake EZ" under Section 511 of the Motor Vehicle
Information and Cost Savings Act. Your application has been reviewed by
our Engineering Evaluation Group. Following are their comments and
requests for clarifications or additional informaion:
1. According to the label on the package, you guarantee that the
consumer will realize at least a 10% improvement in fuel econ-
omy. On what technical basis do you make this claim? Our
experience in the area of brake drag and its influence on fuel
economy indicates improvements of no more than 3% would be pos-
sible, even if brake drag could be completely eliminated. A
value of 10% would only be possible if the standard brake system
was faulty. In such case, this amount of energy lost to the
brakes would surely result in, an enormous amount of heat.
2. Because fuel economy is such an important aspect of current
vehicle production, vehicle . manufacturers have also developed
disk brake systems which reduce drag. These systems are cur-
rently being incorporated on most new passenger cars. In what
model year range is your device most effective. Can your device
be used on new cars?
3. Does your device affect the operation or safety of the vehicle
in any way, e.g., is there any change in free play of the brake
pedal or in the required capacity of the master cylinder?
4. In your application, you recommended that the device be replaced
when the disk pads are replaced. This is not typically required
with OEM brake systems. Does this indicate premature wear due
to the fact that some looseness exists in the device parts as
compared to their OEM counterparts?
5. Comments in the letters supplied with your application indicate
that your device has a relatively high cost. What is the sug-
gested retail price of each of the various models? How are the
kits marketed?
-------
Your responses to the questions above will be required before we can
proceed with the EPA evaluation cf your device. Since we intend to con-
duct these evaluations on a timely basis, we have .established a schedule
for each. Please subrait your response to this" letter by December 21.
In addition, the testimonial letters x?hich you attached to your applica-
tion are not recognized by EPA as valid determination of fuel economy
gains. In order to properly evaluate any change in fuel econony, a
scientifically valid test program should be conducted. The results of
these tests could support your claia for fuel econotsy benefits. I am
prepared to help you develop an appropriate test plan. If you have airy
questions or require further information, please contact we. My tele-
phone number is (313) 663-4299.
Sincerely,
Merrill W. Korth
Device Evaluation Coordinator
Test and Evaluation Branch
bc'c: M. Korth
ECTD:TEB:BEJMA:dkz:X259:2565PlymouthRd:12/1/81:#11510
------- |