From JasonB

EGR Severe Service Brakes is now offering a "Big Caliper" front disk upgrades for several makes and models. The kits include both calipers loaded with state of the art ceramic pads, a pair of kevlar reinforced teflon lines with stainless steel braiding, high temperature synthetic grease and enough Motul 600 DOT 4 Racing Brake fuild for a full system flush. Slotted or drilled rotors are also available. The calipers will fit aftermarket 15" wheels without having to clearance anything (they fit my 15x10 Eagle 589s just fine).

Kits area available for the following applications:

1992-1999 Suburban 1/2 ton 2WD & 4WD
1992-1999 Tahoe, Blazer, Jimmy & Yukon 2WD & 4WD
1994-1998 Dodge Ram 1500 Truck 2WD & 4WD
1992-1998 GMC/Chevy 1/2 ton Trucks 2WD & 4WD

These calipers are much larger than the OEM style single piston calipers and use a 33% larger kidney shaped, vented aluminum piston that allows venting of brake gas buildup and better cooling. The calipers themselves are two peice units by AEROMATICS and include integral cooling fins, and are a direct bolt-in. The new calipers mount to the stock location using greaseless stainless steel guide pins and sleeves riding in bronze oillite bushings. These ensure a low friction operation and prevent "sticky" calipers. OEM calipers use rubber based bushings that degrade with heat and time and allow movement of the caliper. Stiffer bridging over the top of the caliper minimizes caliper flex and helps maintain even pressure over the pad surface.

The kit comes with ceramic pads that have 18% larger surface area than OEM type pads. They also offer 40% more material overall. That means more surface area under braking and results in better heat distribution and dissipation and longer pad life. Since the caliper is larger, it supports the pad over its entire length which reduces deflection of the pads.

Side-by-side comparison of OEM vs New calipers.

Comparison of OEM vs New calipers mounted up.

So, are they worth it?

Well, I installed them on my 1997 Dodge Ram 1500 with 6" of lift and 35" Super Swampers. I do not have four wheel ABS, only the basic RWAL (rear wheel only). Ever since I lifted my truck and put on the larger tires, braking was never the same as stock. RWAL never kicked in, even with the truck loaded. I replaced the front rotors and calipers with OEM type replacements. I also upgraded to semi-metallic pads and braided brake lines. I also kept the rear drums adjusted. The braided brakes lines, from EGR also, firmed up the pedal and did reduce stopping distance, but it didn't stop like it does now. After bedding the new pads, I made several emergency stops from 60 mph and actually locked up the front end and left dual skid marks. Braking distance was better than expected for such speeds. The truck also stayed straight, no longer pulling to one side or the other. In fact, I was able to lock up the front end without holding the steering wheel firmly and the truck continued going straight. Obviously, even my well maintained OEM type guide pins made the calipers stick and pull when hot. The new greasless, self-lubricating guides caused no pulling, even after enough emergency stops that I could smell the brakes.

Any drawbacks?

Only one, and it is not really a drawback, more of an inconvienence. That is the larger pistons require greater volume of fluid as the piston moves outward. This means more pedal travel, just something I did not think about or expect. I think it was an issue for me in the beginning because I had just upgraded to the stainless braided lines earlier and had become accustomed to the much firmer pedal feel the lines offered. However, the "feel" is still firm and better than the completely OEM setup. I have already gotten used to the new feel and an exremely happy with the product. I think that if you are upgrading from a totally stock setup to this kit with the lines and calipers, you should not experience this reduced pedal feel.

I highly recommend this kit to anyone that has larger than stock tires or tows often and would like better braking, less brake fade, and a greater sense of saftey these calipers give you. For a limited time, the entire caliper kit is $799.95 from EGR Servere Service Brakes. Contact Glenn Maurer for more information.

UPDATE: I just wanted to update everyone in regards to the performance of these new calipers during my trip to Moab. They were great. I experienced no brake fade and very consistent brake and pedal feel and performance in all terrain. The outside temps were 90-95 during the peak times of the day and then get up on top of the slickrock that has been baking all day, it is even hotter. We ran Hell's Revenge trail in the afternoon and spent 3 hours driving up countless steep domes and coming down just as many. Some were very steep, steep enough to make walking down the slope difficult. These new calipers made slowly crawling down the slopes very easy and after the first one, I had no hesitation about going down the remaining domes. Each time, the truck was steady and under control. The pedal never hit the floor. Even after 13 hours on the trail doing Poison Spider Mesa, Golden Spike and Gold Bar Rim trails (that is a 15 mile series of hardcore trails if you didn't know) the brakes performed like new. Definately and improvement over the OEM single small piston calipers.

The caliper kit was provided by: EGR Severe Service Brakes. EGR also offers drilled or slotted rotors and the stainless braided lines separately. They also offer a new rear disc brake conversion kit for 1988-2000, 2 & 4wd single rear wheel or larger 17.5 and 19.5 dually models. The kit fits either Dana 70 or 80 full floating axles. These conversion kits include single piston calipers, with or without parking brakes, rotors, hose and all bracketry. For Dodge Ram 1500's, EGR now has a rear drum upgrade kit that includes larger wheel cylinders and two levels of upgraded shoes that have more material on the actual metal backing plate for greater braking surface.

Here are some images of the rear disk conversion (left) and Ram 1500 entire brake upgrade system (right). Note that the calipers in the upgrade are OEM style. The "Big Caliper" is available, as well as extended brake lines for lifted applications.

EGR Severe Service Brakes
1041 Cinnamon Lane
Corona, CA 92882
800-468-2279
Glenn Maurer, Owner