ultimate stopping power

Upgraded performance brake kits
Minimum rim diameter: 17"
X-Line billet 6-piston off-road calipers.
Larger diameter rotor maximized for the truck application
Rotor has internal curved, directional cooling vanes.
Billet caliper mounting brackets.
Stainless steel braided brake lines.
All necessary mounting hardware for quick, easy bolt-on installation.
Comprehensive install and bed-in instructions.

Rotors

The rotors utilized in our X-Line 4×4 big brake kits are crafted from a proprietary high-carbon cast iron alloy, ensuring exceptional durability and stability even during high thermal loads experienced in both street and off-road driving. Notably, these rotors feature curved, directional cooling vanes, significantly enhancing cooling efficiency by maximizing surface area and airflow compared to factory or OEM rotor designs.

For our X-Line 4WD rotors, we employ the proven “AT” slot pattern, striking a fine balance between functional aspects such as efficient removal of sand, mud, and water (especially when driving in rainy conditions or after river crossings) and practical aspects such as minimizing noise, vibration, and harshness (NVH) during braking. This slot pattern also delivers excellent bite and release characteristics.

Every single Powerbrake rotor undergoes precise measurement for run-out and disc thickness variation (DTV) using Swiss measuring equipment. We prioritize quality control without relying on batch or statistical checks – each rotor undergoes individual measurement. Our machining tolerances surpass the industry norm by up to threefold.

Rotor Surface Coating

All our X-Line 4WD rotors feature a proprietary black surface coating. Before applying this coating, the rotors undergo chemical de-greasing to ensure the absence of machining fluids or contaminants that could negatively impact brake performance. The coating exhibits exceptional heat resistance and flexibility, preventing flaking or peeling during the rotor’s thermal expansion and contraction cycles.

Our X-Line 4WD rotors require no solvent-based cleaning or preparation. Simply make sure the car’s hub is clean and install the rotors as they come out of the box. The brake pads will remove the black coating in the pad track areas within the first 4-5 brake applications, while the un-swept areas of the rotor will retain the coating. Although the primary purpose of our rotor coating is to eliminate oils and contaminants during fitting (rather than providing corrosion protection), practical experience has shown that the non-swept areas of our coated X-Line 4WD rotors effectively resist unsightly surface rust formation, depending on environmental conditions. This results in a visually appealing appearance visible through the truck’s wheels and the perfect upgraded performance brake kits.

Rotor Maximum Temperature Recording (MTR) System

All our rotors feature our MTR system that provides a permanent record of the peak operating temperature reached by the rotor. This information is extremely valuable for understanding what is happening in your brake system. The thermal-paint tabs are applied to the outside diameter of the rotors (on both the inboard and outboard rotor plates). Each single-change paint color will change to white when a specific temperature is reached, hereby providing a record of the peak operating temperature of the rotor.

Blue paint changes color at 527 deg F
Green paint changes color at 860 deg F
Orange paint changes color at 1022 deg F
Pink paint changes color at 1166 deg F

Caliper Construction

At Powerbrake, we firmly believe in the advantages of machining our multi-piston calipers from solid billet. All our calipers are precision-machined using high-grade aerospace aluminum billets. Although machining from billet is an expensive manufacturing method, it yields a final product with exceptional strength and rigidity.

How do we offer our billet X-Line 4WD calipers at competitive prices? We achieve this through substantial investments in cutting-edge 5-axis CNC production equipment, ensuring maximum efficiency in caliper machining. The combination of machining from billet and the caliper designs enhanced through Finite Element Analysis (FEA) results in calipers with an impressive rigidity-to-size ratio. The slender profile of the calipers reduces unsprung weight and enhances wheel clearance.

Caliper Surface Finish

Our X-Line 4WD calipers are offered in two finish options: Red anodize (type-2) or Dark Gray hard anodize (type-3). The anodize dyes chosen for our Red finish provide excellent UV and temperature resistance, ensuring long-term color retention. The Dark Gray hard anodize is our most resilient finish.

Caliper Logos

Our logos and other markings are applied to our calipers using advanced laser technology. This creates visually appealing contrast between the logo and the caliper color. The logos on our X-Line 4WD calipers will not be damaged by heat, brake fluid or solvents, as is the case with paint in-lay logos used by many of our competitors. Brake calipers operate in a very challenging environment. They are exposed to dirt, carbonized brake pad material, constantly fluctuating temperatures and constantly changing environmental conditions. Powerbrake has focused on ensuring that our X-Line 4WD brake calipers will remain looking good under the widest possible range of operating conditions.

Caliper Cross-Bolts

The high-tensile caliper cross-bolts used in the assembly of our X-Line 4WD calipers are European sourced and coated with a silver zinc flake coating. This coating offers exceptional corrosion resistance, while having no negative effect on bolt strength at all. The bolt positions of our X-Line 4×4 calipers are the result of extensive FEA analysis and deliver optimum caliper rigidity. The cross-bolts are inserted into the caliper from the inboard side resulting in maximum wheel clearance which is important on 4WD trucks.

Caliper Pistons

Powerbrake X-Line 4WD calipers are equipped with stainless steel pistons. While manufacturing caliper pistons from stainless steel is considerably more expensive than using aluminum pistons like many of our competitors, the benefits justify the investment. Stainless steel has a significantly slower heat transfer rate compared to aluminum. As a result, stainless steel pistons slow down the heat transfer from the brake pads to the caliper seals and brake fluid. This reduces the risk of brake fluid boiling and extends the lifespan of the seals. Our caliper pistons are crafted from a special grade of stainless steel that boasts more than double the strength of regular 304-grade stainless steel (in terms of yield and ultimate tensile strengths), while maintaining the same level of corrosion resistance.

Internal Fluid Crossovers

Our X-Line 4WD calipers feature internal fluid crossovers and hidden bleed screws for protection against damage from stone impacts. Every part of the X-Line 4WD caliper is aimed at maximum usability and durability in tough off-road or dirt road conditions.

Caliper Maximum Temperature Recording (MTR) System

All Powerbrake X-Line 4WD calipers come equipped with our MTR system, which offers a permanent record of the caliper’s maximum operating temperature. This feature is highly valued by customers as it provides valuable data for making informed decisions regarding brake fluid selection and more. The inclusion of the Max Temp Recording system, at no additional cost, sets Powerbrake apart as a unique offering in the global market.

Caliper Hardware

All other caliper hardware components (including: pad retaining pins, bleed screws and pad abutments) are manufactured from stainless steel to ensure the highest levels of corrosion resistance.

Caliper Mounting Brackets

X-Line 4WD caliper mounting brackets are meticulously machined from billet aircraft-grade aluminum alloy, FEA enhanced for optimal strength and rigidity, and hard anodized (type-3). It is important to note that we utilize stainless steel thread inserts for the radial mount bolts that secure our X-Line 4WD calipers to the caliper mounting brackets. This is due to the solid caliper reinforcement bridge featured in our X-Line 4WD calipers, which requires the removal of the two caliper radial mount bolts for pad replacement. By using thread inserts in our mounting brackets, we ensure maximum thread strength and durability. Similar thread inserts are widely employed in the aerospace industry, thanks to their superior strength compared to conventional aluminum threads.

Brake Lines

The brake lines included with our X-Line 4WD big brake kits feature an extruded Teflon inner lining that is highly resistant to the aggressive chemical properties of modern brake fluids, as well as being able to handle far higher temperatures than rubber. The Teflon lining is covered by strands of tightly woven stainless steel braid that acts as the muscle of the hose, providing incredible resistance to expansion under pressure. Our stainless braid is covered with a polymeric outer layer that prevents dirt from getting between the stainless braid and the Teflon inner lining. The resulting hose assemblies offer the best possible pedal feel, matched to excellent durability and corrosion resistance.

Brake Pads

The Powerbrake X-Line 4WD calipers (our upgraded brake kits) are designed around a pad profile which is available in wide range of brake pad compounds from most pad manufacturers worldwide. Our PB05 brake pad compound is in our opinion the very best pad compound on the world market for 4WD trucks. This ultra-high-performance material offers a big step up in performance and fade resistance over the pads that originally come with the truck. Stopping power, pedal feel and modulation are simply unmatched. In addition to the class-leading performance this pad compound will offer a good wear life and mileage.

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