The World Leaders in Brake Upgrades for 4WD Trucks
Safety Performance Durability Technology
X-Line
Big Brake Kits
D-Line
Rotor & Pad Kits
A cost-effective upgrade in performance over factory brakes. This kit includes a pair of Powerbrake D-Line high-performance rotors and an axle set of matched high-performance brake pads.
Our D-Line rotors are cast from a proprietary high-carbon alloy. Pads are the same profile as the factory pads and are direct replacement items for the standard manufacturer caliper, and the pad compounds have been specifically selected for use on 4WD vehicles. The kit also includes comprehensive fitment and bed-in instructions.
Our rotors are machined to tolerances up to three times tighter than the industry norm and all Powerbrake rotors feature our MTR (Max Temperature Recording) system. Proprietary black rotor surface coating ensures quicker bed-in and max brake performance.
Why should you consider upgrading your brakes?
The rapid worldwide growth in modifying civilian 4wd vehicles has created a significant need for well-engineered brake upgrade solutions, Overland enthusiasts are fitting roof-top tents, bull bars, long-range fuel tanks, water tanks, additional battery systems, storage systems, additional spare wheels etc. All of these accessories significantly increase vehicle weight, which severely affects brake performance and results in increased stopping distances.
Larger wheel and tyre packages are also becoming increasingly popular. These generally weigh a lot more than factory-fitted wheels and tyres. This additional rotational mass again severely affects brake performance, leading to increased stopping distances, Many 4wd enthusiasts are also tuning their vehicles, adding significant horsepower. More speed = more energy, resulting in increased brake temperatures and ultimately brake fade.
Powerbrake X-Line 4wd big brake kits are engineered from the ground up to be the ultimate brake upgrades available on the world market for 4wd vehicles. They deliver significantly improved brake performance, reduce brake fade and vastly improve pedal feel and modulation.
The performance gains achieved when fitting our big brake kits vastly outweigh the benefits that can be achieved by fitting upgraded, standard-diameter discs and pads. Our civilian X-Line 4wd big brake kits feature direct technology transfer from our R-Line off-road race brake systems that have been used by works race teams to win multiple FIA Cross Country World Championships as well the infamous Dakar Rally (which is regarded by many to be the most gruelling motorsport event on earth).
Why Choose Powerbrake?
Our World Championship-winning R-Line off-road race brake systems have proven themselves over more than a decade in race conditions ranging from the scorching deserts of South America, the Middle East and Africa to the snow-covered forests of Northern Russia, to the fast gravel tracks of Mongolia in the hands of the world’s best off-road race car drivers. Our civilian X-Line 4WD big brake kits were designed by the same team that designed our renowned R-Line off-road race systems and they are manufactured on the same state-of-the-art equipment, in the same factory.
All design features found in our civilian X-Line 4WD big brake kits were directly developed through our extensive involvement at the highest levels of international off-road racing. The exact same technology, features and materials found in our Dakar Rally-winning R-Line off-road race brake systems can be found in our civilian X-Line 4WD big brake kits. When we claim “direct technology transfer” from our race to our civilian brake systems, we mean it. Every single feature in our X-Line 4WD calipers can also be found in our current production R-line off-road race calipers that we supply to leading Dakar Rally teams.
What will an X-Line big brake kit do for you?
Powerbrake X-Line 4WD big brake kits are engineered from the ground up to be the ultimate brake upgrades available on the world market for 4WD vehicles. They deliver significantly improved brake performance, reduce brake fade and vastly improve pedal feel and modulation. The performance gains achieved when fitting our big brake kits vastly outweigh the benefits that can be achieved by fitting upgraded, standard diameter discs and pads. Our civilian X-Line 4WD big brake kits feature direct technology transfer from our R-Line off-road race brake systems that have been used by works race teams to win multiple FIA Cross Country World Championships as well the infamous Dakar Rally (which is regarded by many to be the most gruelling motorsport event on earth).
What will a high performance D-Line rotor and pad kit do for you?
Powerbrake D-Line high performance rotor and pad kits are engineered from the ground up to improve brake performance and reduce brake fade on your 4WD vehicle. While our D-Line rotor and pad kits are our entry-level brake upgrade option for 4wd vehicles, they will deliver considerable performance advantages at a relatively affordable price point. We have sold tens of thousands of our matched rotor and pad upgrade kits since their launch in 2004 and the number of customers that have returned time and again for these kits after fitting their first kit speaks to the performance of the product. While we are always very happy to see new customers fitting our D-Line kits, it is the number of return customers that we like to see most. We have many customers that immediately order a Powerbrake rotor and pad kit each time they purchase a new vehicle.
What does an X-Line 4x4 Big Brake Kit include?
- X-Line billet 6-piston off-road calipers (featuring stainless steel pistons, internal fluid crossovers, protected bleed screws, internal wiper seals, ultra high-temp pressure seals, all stainless steel hardware, MTR max temp recording system and pad anti-rattle springs).
- High-performance brake pads, pre-loaded into the calipers (featuring OE quality anti-squeal shims).
- Large 350x34mm 1-Piece slotted discs (featuring 48 x curved / directional cooling vanes per disc, MTR max temp recording system and our proprietary black coating that ensures fastest bed-in time).
- Billet caliper mounting brackets (featuring stainless steel thread inserts for the radial mount bolts for max service life).
- Stainless steel braided brake lines (featuring stainless steel end fittings, PVC protective cover, Teflon hose inner and 32 x braid structure).
- All necessary mounting hardware for quick, easy bolt-on installation.
- Comprehensive fitment and bed-in instructions.
What does a D-Line Kit include?
- 2 x Standard diameter AT-Series high performance slotted discs.
- An axle set of matched high-performance brake pads.
- Fits as per a standard disc an pad change, using the vehicle’s standard OEM calipers.
What are the benefits at a glance?
- Reduced stopping distances in both wet and dry conditions.
- Reduced brake fade and improved brake consistency.
- Improved initial brake response (bite).
- Improved brake modulation particularly during emergency stops.
- Improved resistance to rotor distortion (warping) and cracking at high temperatures.
Billet 6 Piston Caliper Construction
At Powerbrake, we believe strongly in the benefits of machining our multi-piston calipers from solid billet. All of our championship winning X-Line and R-Line race calipers are machined from high-grade aerospace aluminum billets, and we’ve chosen to manufacture the X-Line 4WD range from the same material. Machining from billet is admittedly an expensive way to manufacture calipers but it results in a finished product that exhibits exceptional levels of strength and rigidity.
How do we bring our billet X-Line 4WD calipers to the market at such competitive prices? Through significant investment in state-of-the-art 5-axis CNC production equipment that allows us to machine the calipers with maximum efficiency. The fact that we machine all of our calipers from billet, matched to the FEA enhanced caliper designs themselves, results in calipers with an impressive rigidity to overall size ratio. The slim profile of the calipers reduces un-sprung weight and aids with wheel clearance.
Our X-Line 4WD calipers (like their Dakar-spec R-Line counterparts) 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 4WD conditions.
Our X-Line 4WD calipers are available in two finish options. Either a Red anodize (type-2) or a Dark Grey hard hard anodize (type-3). The anodize dyes used for our Red finish have been carefully selected to offer the maximum UV and temperature resistance to ensure long-term colour retention. The Dark Grey hard anodise is our most durable finish and is the finish that we use on all of our R-Line off-road race calipers.
Powerbrake X-Line 4WD calipers all feature stainless steel pistons. Stainless steel is significantly more expensive to manufacture caliper pistons from than the aluminum pistons used by many of our competitors but the benefits are well worth the investment. Stainless steel transfers heat far slower than aluminum. The result is that stainless steel pistons slow the transfer of heat from the brake pads to the calipers seals and brake fluid, hereby reducing the chances of boiling brake fluid and also extending seal life. Our caliper pistons are manufactured by a special grade of stainless steel that is more than twice as strong as regular 304-grade (in terms of yield and ultimate tensile strengths), while maintain the same levels of corrosion resistance.
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 4WD 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.
All Powerbrake X-Line 4WD calipers feature our MTR system. The system provides a permanent record of the maximum operating temperature reached by the caliper. Feedback from our R-Line race customers has been extremely positive with regards to the MTR system over the years. We therefore decided to apply this same technology to our X-Line 4WD calipers. Customers will really appreciate this feature as it provides valuable data in the support of brake fluid choice etc. The inclusion of a Max Temp Recording system on civilian big brake kit range at no extra charge is unique to Powerbrake on the world market.
All other caliper hardware components (including: pad retaining pins, bleed screws and pad abutments) are manufactured from stainless steel to ensure highest levels of corrosion resistance.
Brake Simulation Software
As with all Powerbrake big brake kits, each X-Line 4WD kit is tailored to the specific target vehicle. This involves careful software modelling of correct brake balance, brake torque outputs and pedal feel using our proprietary brake simulation software (developed in-house) which is a key element in the success of our X-Line 4WD big brake kits. The software allows us to enter all aspects of the factory brake system on the car as well as all key data affecting chassis dynamics under braking. Our engineers can then simulate braking events at various negative G’s and analyse dynamic weight transfer for the chassis in question.
They are then able to perfectly optimise brake torque outputs delivered by our big brake kit by changing disc diameters, caliper piston ratios and brake pad friction co-efficient. The result is that the caliper piston diameters / ratios, disc sizes and pad compounds in each kit are tailored to the vehicle platform in question. Our X-Line 4WD big brake kits will perfectly integrate with the ABS, EBD and other stability control systems on the vehicle. When driving a vehicle fitted with a Powerbrake X-Line 4WD big brake kit, you will feel this attention to detail coming through by the way that the vehicle chassis reacts under braking.
Rotor Surface Coating
All our X-Line 4wd rotor rings are coated with a proprietary black surface coating. The rotors are chemically de-greased before the application of this coating to ensure that no machining fluids or other contaminants that can be absorbed the brake pads and negatively affect brake performance are present on our rotors at all. The coating is able to withstand extremely high temperatures and is flexible enough to expand and contract without flaking or peeling off of the rotor surface during the constant thermal expansion and contraction cycles experienced by the brake rotor.
Our X-Line 4wd rotors require no cleaning or preparation using solvents at all. Simply ensure that the car’s hub is clean and fit the rotors as they come out of the box. The black coating will be removed by the brake pads in the pad track areas within the first 4-5 brake applications. The un-swept areas of the rotor will remain coated. While our rotor coating was primarily designed to ensure that there was zero presence of oils and contaminants on our rotor surfaces at the time of fitting (and was not in fact designed to provide corrosion protection), practical experience has shown that the non-swept areas of our coated X-Line 4wd rotors will in fact resist the common formation of unsightly surface rust on the non-swept areas of the rotors quite well (depending on environmental conditions in your area). This results in a far more visually appealing assembly visible through the car’s wheels.
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 32 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 end fittings on our hoses are all machined from grade-304 stainless steel as opposed to the plated, mild steel fittings used by many of our competitors. The resulting hose assemblies offer the best possible pedal feel, matched to excellent durability and corrosion resistance.
Caliper Mounting Brackets
X-Line 4WD caliper mounting brackets are machined from billet aircraft grade aluminium alloy, FEA enhanced for strength and rigidity and (type-3) hard anodised. One detail to note is that we use stainless steel thread inserts for the radial mount bolts that secure our X-Line 4WD calipers to the caliper mounting brackets. Since our X-Line 4WD calipers feature a solid caliper re-enforcement bridge, you need to remove the two caliper radial mount bolts in order to change pads. For this reason we use thread insert in our mounting brackets to achieve maximum thread strength and durability. Similar thread inserts are used extensively used in the aerospace industry due to their increased strength over conventional aluminum threads.
Caliper Logos
Our logos and other markings are applied to our calipers using advanced laser technology. This creates a visually appealing contrast between the logo and the caliper colour. 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, carbonised 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.
Rotor Technology explained
Talking about POWERBRAKE
From Our Family To Yours
Founded in South Africa two decades ago, Powerbrake remains a family-owned business driven by a deep passion for overlanding and safety. Our mission is to deliver the highest-quality brake upgrade solutions, designed to protect your family on every journey.
