StopTech 98-180-1470 User Manual

Installation Instructions

Corvette C5

1997 - 2004

355mm Front

Big Brake Upgrade

ST-40 Caliper

98-180-1470 Rev . C 03-02-06

CC

OMPONENT IDENTIFICAOMPONENT IDENTIFICA

C

OMPONENT IDENTIFICA

CC

OMPONENT IDENTIFICAOMPONENT IDENTIFICA

355mm AeroRotor and Hat Assembly

ST -40 Caliper

TIONTION

TION

TIONTION

Stainless Braided Brake Line and Hardware

High-Performance Street Pads

BB

ig Big B

B

ig B

BB

ig Big B

(This is a representative photograph. The actual components in

3541 Unit A, Lomita Boulevard, Torrance, CA 90505 [phone]
www.stoptech.com 2

rake Krake K

rake K

rake Krake K

your kit may appear slightly different.)

it for the Corit for the Cor

it for the Cor

it for the Corit for the Cor

vv

ette C5ette C5

v

ette C5

vv

ette C5ette C5

Caliper Bracket

APPLICAAPPLICA

APPLICA

APPLICAAPPLICA

Caliper ClearanceCaliper Clearance

Caliper Clearance

Caliper ClearanceCaliper Clearance

Most 17” wheels will clear the outer diameter of the caliper for a 328mm or 332mm rotor kit. F or a
355mm kit, a minimum 18” wheel is typically required, and for a 380mm rotor kit, a minimum 19”
wheel is needed. The more critical clearance, however, is the gap between the spokes of the wheel
and the face of the caliper. Do not assume that a larger-diameter wheel will automatically clear the
face of the caliper.

To determine the actual metal-to-metal distance from the stock rotor face to the inside of the wheel
spokes, refer to the StopTech website at
in the ‘Technical Information’ section. Review the instructions carefully, to ensure that you have a
full understanding of how to accurately measure the critical wheel clearances.

It is very important that you verify the accuracy of the scale of the printout by matching both a
width and length dimension on your vehicle. Dimensions are shown in millimeters, but one di­mension in each direction is also shown in inches, and StopTech recommends adding at least 2mm
of additional clearance to these dimensions. Follow the instructions carefully, to produce a fitment
template, and take care to ensure that your measurements are very precise. If you have any ques­tions or difficulties, please contact the StopTech Customer Service Department on [phone] ­extension 105, or send an e-mail to

TION DISCLTION DISCL

TION DISCL

TION DISCLTION DISCL

wwwwww

.stoptech.com.stoptech.com

www

.stoptech.com, and click on the ‘Wheel Fitment’ link

wwwwww

.stoptech.com.stoptech.com

[e-mail]

[e-mail].

[e-mail]

AIMERAIMER

AIMER

AIMERAIMER

NN

ote: Fote: F

N

ote: F

NN

ote: Fote: F

Wheel SpacersWheel Spacers

Wheel Spacers

Wheel SpacersWheel Spacers

Wheel spacers can provide extra clearance to the outer face of the caliper . This will also space out the
entire wheel, widening the track width of the vehicle. Fender clearances should be checked on
lowered cars, and longer lug studs or wheel bolts are usually required.

Note: The Wheel Industry Council has issued guidelines advising that wheel spacers not beNote: The Wheel Industry Council has issued guidelines advising that wheel spacers not be

Note: The Wheel Industry Council has issued guidelines advising that wheel spacers not be

Note: The Wheel Industry Council has issued guidelines advising that wheel spacers not beNote: The Wheel Industry Council has issued guidelines advising that wheel spacers not be
used. It is the responsibility of the customer to ensure that wheel spacers are properlyused. It is the responsibility of the customer to ensure that wheel spacers are properly

used. It is the responsibility of the customer to ensure that wheel spacers are properly

used. It is the responsibility of the customer to ensure that wheel spacers are properlyused. It is the responsibility of the customer to ensure that wheel spacers are properly
specified and installed.specified and installed.

specified and installed.

specified and installed.specified and installed.

CC

aliperaliper

C

aliper

CC

aliperaliper

Many wheel-cleaning solutions contain strong acids that may damage the finish on any caliper or
aluminum anodized finish, especially the plating on the hardware. Check for adverse effects by
trying a small amount of the cleaner in question on an inconspicuous area. Avoid over-spraying,
and rinse cleaning solutions off as quickly as possible. StopTech is not liable for damage to calipers,
hats or bracket finishes, due to corrosive chemical exposure.

inal fitment of the wheel to the caliper is the rinal fitment of the wheel to the caliper is the r

inal fitment of the wheel to the caliper is the r

inal fitment of the wheel to the caliper is the rinal fitment of the wheel to the caliper is the r

, H, H

at and Bat and B

, H

at and B

, H, H

at and Bat and B

racket Fracket F

racket F

racket Fracket F

inish Dinish D

inish D

inish Dinish D

isclaimerisclaimer

isclaimer

isclaimerisclaimer

esponsibility of the customeresponsibility of the customer

esponsibility of the customer

esponsibility of the customeresponsibility of the customer

..

.

..

3541 Unit A, Lomita Boulevard, Torrance, CA 90505 [phone]
www.stoptech.com 3

APPLICAAPPLICA

APPLICA

APPLICAAPPLICA

BB

rake Nrake N

B

rake N

BB

rake Nrake N

Certain brake pad compounds make more noise than others. Proper anti-squeal shim plates be­tween the caliper pistons and backing plate of the pad help to reduce the problem. Anti-squeal
lubricants are also available, to reduce some of the noise. The reality is that performance pads are
more prone to brake squeal.

Note: The customer is responsible for any squeal-related problems due to pad selection.Note: The customer is responsible for any squeal-related problems due to pad selection.

Note: The customer is responsible for any squeal-related problems due to pad selection.

Note: The customer is responsible for any squeal-related problems due to pad selection.Note: The customer is responsible for any squeal-related problems due to pad selection.

PP

erer

manent Mmanent M

P

er

manent M

PP

erer

manent Mmanent M

It may be necessary to grind a portion of each lower ball joint, to clear the inboard face of the rotor
during full suspension travel. If done carefully, this modification will not affect the strength or
structural integrity of the vehicle. Although a coarse file will remove the material, a power grinder,
if used properly, will be more efficient. If you are uncomfortable making this modification, seek
the help of a qualified professional.

oiseoise

oise

oiseoise

odification to Loodification to Lo

odification to Lo

odification to Loodification to Lo

TION DISCLTION DISCL

TION DISCL

TION DISCLTION DISCL

ww

er Ber B

all Jall J

w

ww

er B

er Ber B

all J

all Jall J

ointsoints

oints

ointsoints

AIMER (ContAIMER (Cont

AIMER (Cont

AIMER (ContAIMER (Cont

’’

d.)d.)

’

d.)

’’

d.)d.)

BB

rake rake

B

rake

BB

rake rake

The most common cause of brake vibration is improper bed-in of pads and rotors, or improper pad
selection for the specific driving environment. Rotor run-out may also cause vibration, but preci­sion manufacturing and inspection typically mean that run-out is not an issue. Modern produc­tion methods ensure that the rotor run-out is within +/- 0.002” when installed on a StopTech alumi­num hat, and it controls thickness variation to within 0.0003”. Under the most extr eme conditions,
any rotor may warp, but uneven pad deposition is a more typical cause of vibration. If the system
is not properly bedded-in, or if street pads are run on an open track, unev en pad deposits will occur,
causing an ever-worsening vibration. Failure to immediately address a pad deposition/vibration
issue may lead to permanent damage of the rotors. Please read and understand the bed-in proce­dure included in this manual. If you have any questions, please contact the StopTech Customer
Service Department on [phone] - extension 105, or you can e-mail directly to
[e-mail]@stoptech.com

[e-mail].

[e-mail]

NN

ote: Sote: S

N

ote: S

NN

ote: Sote: S

pads and rotors.pads and rotors.

pads and rotors.

pads and rotors.pads and rotors.

All trademarAll trademar

All trademar

All trademarAll trademar
ated nor affiliated with, nor sponsored by General Motors.ated nor affiliated with, nor sponsored by General Motors.

ated nor affiliated with, nor sponsored by General Motors.

ated nor affiliated with, nor sponsored by General Motors.ated nor affiliated with, nor sponsored by General Motors.

Vibration - Vibration -

Vibration -

Vibration - Vibration -

topTtopT

ech is not liable for vibrech is not liable for vibr

topT

ech is not liable for vibr

topTtopT

ech is not liable for vibrech is not liable for vibr

ks arks ar

ks ar

ks arks ar

THIS IS IMPORTHIS IS IMPOR

THIS IS IMPOR

THIS IS IMPORTHIS IS IMPOR

e pre pr

operoper

e pr

e pre pr

ties of their rties of their r

oper

ties of their r

operoper

ties of their rties of their r

TT

ANT!ANT!

T

ANT!

TT

ANT!ANT!

ations caused by eations caused by e

ations caused by e

ations caused by eations caused by e

espectivespectiv

espectiv

espectivespectiv

e oe o

wners. Swners. S

e o

wners. S

e oe o

wners. Swners. S

xtrxtr

eme usage or impreme usage or impr

xtr

eme usage or impr

xtrxtr

eme usage or impreme usage or impr

topTtopT

topT

topTtopT

ech LLech LL

ech LL

ech LLech LL

C is neither associ-C is neither associ-

C is neither associ-

C is neither associ-C is neither associ-

oper bed-in ofoper bed-in of

oper bed-in of

oper bed-in ofoper bed-in of

3541 Unit A, Lomita Boulevard, Torrance, CA 90505 [phone]
www.stoptech.com 4

II

mpormpor

I

mpor

II

mpormpor

Wheel FitmentWheel Fitment

Wheel Fitment

Wheel FitmentWheel Fitment

Do not assume that your wheels will fit. An outline drawing of your StopTech Big Brake kit is
available in the ‘Technical Information’ section of our website at
distance from the outer face of your stock caliper to the inner face of your wheel spokes, or make a
template according to the instructions on the website, to determine if a wheel spacer is necessary.

DO THIS BEFORE YOU INST ALL YOUR KIT!

Cleaning of RotorsCleaning of Rotors

Cleaning of Rotors

Cleaning of RotorsCleaning of Rotors

The AeroRotors supplied with this kit are coated with a water-soluble, environmentally friendly
rust inhibitor. This coating MUST BE WASHED OFF WITH SOAP AND WATER before installa­tion. Brake cleaner is not as effective as soap and water. Even if it doesn’t look as if anything is
coming off the rotor, the rust inhibitor is there, and must be entirely cleaned. Rotors will quickly
rust without protection, so if the rotor is not rusty, it’s still coated. After cleaning, you may see the
rotor start to develop a slight rust color. This is normal, and indicates that all of the rust inhibitor
has been removed.

RR

otor and Potor and P

R

otor and P

RR

otor and Potor and P

Proper rotor and pad bed-in is essential to the performance of your new brake system. Failure to
properly bed-in the brakes will seriously impact how well they work, and how long they will last.
The number one cause of brake vibration is uneven pad material deposition on the rotor. Proper
bed-in will greatly minimize such problems. Follow, as closely as possible, the bed-in procedure
detailed later in this manual, or refer to the StopTech website at
information.

ad Bed-inad Bed-in

ad Bed-in

ad Bed-inad Bed-in

tant Ntant N

tant N

tant Ntant N

oticesotices

otices

oticesotices

wwwwww

.stoptech.com.stoptech.com

www

.stoptech.com. Measure the

wwwwww

.stoptech.com.stoptech.com

wwwwww

.stoptech.com.stoptech.com

www

.stoptech.com for fur ther

wwwwww

.stoptech.com.stoptech.com

SS

afety Nafety N

S

afety N

SS

afety Nafety N

Improper handling of a vehicle, especially while raised and supported by jack stands, ramps or
other mechanical means, can cause serious bodily injury or even death. It is strongly recommended
that a trained, experienced mechanic, with proper equipment, install the Big Brake Kit supplied by
StopTech LLC. StopTech LLC assumes no liability , expr essed or implied, for the improper installa­tion or use of this product or its components.

Liability NLiability N

Liability N

Liability NLiability N

Automobile racing and performance driving, whether sanctioned or not, on or off the road, are
dangerous. Products used in such environments/applications are subject to stresses and conditions
outside of normal use, wear and tear. All equipment sold or provided by StopTech LLC is sold
WITHOUT WARRANT Y, EXPRESSED OR IMPLIED. No warranty or representation is made to
the product’s ability to protect the user from injury or death. The user assumes all risk. StopTech
LLC is NOT responsible for any damage, consequential or otherwise, for equipment failure or mal­performance after installation. Under no circumstances is StopTech liable for labor charges or loss
of use.

Contact SContact S

Contact S

Contact SContact S

If you have any questions about wheel fitment, rotor cleaning, or bed-in of a particular pad type,
please call StopTech’s Customer S ervice Department on [phone] - extension 105, or y ou can
e-mail directly to

oticeotice

otice

oticeotice

o o

o

o o

topTtopT

topT

topTtopT

WW

arrantyarranty

W

arranty

WW

arrantyarranty

echech

ech

echech

[e-mail]

[e-mail].

[e-mail]

3541 Unit A, Lomita Boulevard, Torrance, CA 90505 [phone]
www.stoptech.com 5

CorCor

Cor

CorCor

Note: It is important to read and understand this ENTIRE installation manual, includingNote: It is important to read and understand this ENTIRE installation manual, including

Note: It is important to read and understand this ENTIRE installation manual, including

Note: It is important to read and understand this ENTIRE installation manual, includingNote: It is important to read and understand this ENTIRE installation manual, including
the bed-in procedure, before starting the installation.the bed-in procedure, before starting the installation.

the bed-in procedure, before starting the installation.

the bed-in procedure, before starting the installation.the bed-in procedure, before starting the installation.

Kit ContentsKit Contents

Kit Contents

Kit ContentsKit Contents

Your StopTech Big Brake kit includes the following:
1 pair of ST-40 four-piston calipers, sized specifically for your vehicle
1 set of high-performance street pads (not suitable for track use)
1 pair of 355 x 32mm two-piece rotor assemblies
1 pair of aluminum caliper adapter brackets
2 pair of 7/16-20 self-locking Jet nuts
2 pair of 12mm washers
1 pair of stainless steel brake lines
1 pair of banjo bolts
2 pair of copper crush washers
1 pair of rubber end caps
1 caplet of Loctite 262

TT

ools and Eools and E

T

ools and E

TT

ools and Eools and E

Note: Different models and years of vehicle use different-sized fasteners, and every effort hasNote: Different models and years of vehicle use different-sized fasteners, and every effort has

Note: Different models and years of vehicle use different-sized fasteners, and every effort has

Note: Different models and years of vehicle use different-sized fasteners, and every effort hasNote: Different models and years of vehicle use different-sized fasteners, and every effort has
been taken to correctly identify the proper sized tool for each step of the installation. Occa-been taken to correctly identify the proper sized tool for each step of the installation. Occa-

been taken to correctly identify the proper sized tool for each step of the installation. Occa-

been taken to correctly identify the proper sized tool for each step of the installation. Occa-been taken to correctly identify the proper sized tool for each step of the installation. Occa­sionallysionally

sionally

sionallysionally
tool correctly fits the fastener before loosening or tightening it.tool correctly fits the fastener before loosening or tightening it.

tool correctly fits the fastener before loosening or tightening it.

tool correctly fits the fastener before loosening or tightening it.tool correctly fits the fastener before loosening or tightening it.

, ho, ho

, ho

, ho, ho

quipment Rquipment R

quipment R

quipment Rquipment R

ww

evev

erer

, manufactur, manufactur

w

ev

er

, manufactur

ww

evev

erer

, manufactur, manufactur

vv

ette C5 Fette C5 F

v

ette C5 F

vv

ette C5 Fette C5 F

equirequir

equir

equirequir

eded

ed

eded

ers use alterers use alter

ers use alter

ers use alterers use alter

rr

ont Axle Kont Axle K

r

ont Axle K

rr

ont Axle Kont Axle K

nate fasteners, so itnate fasteners, so it

nate fasteners, so it

nate fasteners, so itnate fasteners, so it

itit

it

itit

’’

s advisable to check that eachs advisable to check that each

’

s advisable to check that each

’’

s advisable to check that eachs advisable to check that each

The following tools and equipment will be needed:
21mm wrench or socket (1/2” drive suggested)
14mm wrench or socket
13mm flare wrench
11mm box wrench
11/16” wrench
1/2” wrench or socket (3/8” drive suggested)
Torque wrenches capable of 10-125 lb-ft settings
5mm Allen (hex) wrench
Needle-nose or small standard pliers
Coarse file or power grinder
Anti-seize compound
Small drip tray or several rags
Small funnel or suitable means of filling master cylinder reservoir
Brake bleed bottle
Plastic or non-marring mallet
1 pair of jack stands or other means of supporting vehicle
DOT 3 or 4 Brake Fluid (Check manufacturer’s recommendation for compatibility. StopTech rec­ommends flushing brake fluid every one-to-two years, or more often under severe usage conditions.
If not done recently, the installation of a brake kit is an excellent opportunity to refresh your brake
fluid, or to upgrade to a higher-performance fluid, such as Motul 600.)

3541 Unit A, Lomita Boulevard, Torrance, CA 90505 [phone]
www.stoptech.com 6

Step 1Step 1

Step 1

Step 1Step 1
RR

aise aise

VV

R

aise

RR

aise aise

NN

ote: All photographs show a right-hand side installation, unless otherwise noted.ote: All photographs show a right-hand side installation, unless otherwise noted.

ote: All photographs show a right-hand side installation, unless otherwise noted.

N

ote: All photographs show a right-hand side installation, unless otherwise noted.ote: All photographs show a right-hand side installation, unless otherwise noted.

NN

A level, stable and clean surface, suitable for sup­porting the vehicle on jack-stands, should be
used for the installation.

WW

arar

W

ar

WW

arar

with only a jack. Always use jack-stands.with only a jack. Always use jack-stands.

with only a jack. Always use jack-stands.

with only a jack. Always use jack-stands.with only a jack. Always use jack-stands.

For a front kit installation, apply the parking
brake, then break loose the lug nuts on both
front wheels before jacking up the vehicle.

Jack up the vehicle, and secure it on a pair of
jack-stands, referring to the owner’s manual to
identify the correct jack and support locations.

ehicle, and Rehicle, and R

V

ehicle, and R

VV

ehicle, and Rehicle, and R

ning: Nning: N

ning: N

ning: Nning: N

evev

ev

evev

er leaver leav

er leav

er leaver leav

emoemo

emo

emoemo

e any ve any v

e any v

e any ve any v

vv

e e

WheelsWheels

v

e

Wheels

vv

e e

WheelsWheels

ehicle supporehicle suppor

ehicle suppor

ehicle supporehicle suppor

tedted

ted

tedted

After securing the vehicle at a convenient height,
remove the front wheels.

NN

ote: Tote: T

N

ote: T

ote: Tote: T

NN

must be applied before removing the frontmust be applied before removing the front

must be applied before removing the front

must be applied before removing the frontmust be applied before removing the front
wheels.wheels.

wheels.

wheels.wheels.

If necessary, place a wheel nut on one of the
studs, to prevent the rotor from falling.

To make it easier to access the brake line fittings,
turn the steering either toward or away from the
side that you’re working on, depending on the
orientation of the caliper.

If you’re installing a leading caliper, turn the
steering toward the side that y ou’ r e working on,
and if you’re installing a trailing caliper, turn
the steering away from the side that you ’ re work­ing on. This will make access to the caliper bolts
easier.

o ensuro ensur

o ensur

o ensuro ensur

e safetye safety

e safety

e safetye safety

, the par, the par

, the par

, the par, the par

king brking br

king br

king brking br

akeake

ake

akeake

3541 Unit A, Lomita Boulevard, Torrance, CA 90505 [phone]
www.stoptech.com 7

Step 2Step 2

Step 2

Step 2Step 2
Disconnect Stock Brake LineDisconnect Stock Brake Line

Disconnect Stock Brake Line

Disconnect Stock Brake LineDisconnect Stock Brake Line

WW

arar

ning: Bning: B

W

ar

ning: B

WW

arar

ning: Bning: B

fluid from any painted surface. Also be sure that the cap is securely installed on the masterfluid from any painted surface. Also be sure that the cap is securely installed on the master

fluid from any painted surface. Also be sure that the cap is securely installed on the master

fluid from any painted surface. Also be sure that the cap is securely installed on the masterfluid from any painted surface. Also be sure that the cap is securely installed on the master
cylindercylinder

cylinder

cylindercylinder
installation.installation.

installation.

installation.installation.

Place a drip tray or several rags directly below
the inboard brake line connection. If the area
around the brake line connection to the chassis
is dirty, clean it using brake cleaner or an ap­propriate cleaning agent.

Use a 13mm flare wrench to slightly loosen the
hard line fitting.

rr

ake fluid will damage most painted surake fluid will damage most painted sur

r

ake fluid will damage most painted sur

rr

ake fluid will damage most painted surake fluid will damage most painted sur

. If the cap is loose or r. If the cap is loose or r

. If the cap is loose or r

. If the cap is loose or r. If the cap is loose or r

emoemo

vv

ed, it is likely that mored, it is likely that mor

emo

v

ed, it is likely that mor

emoemo

vv

ed, it is likely that mored, it is likely that mor

faces. Ifaces. I

faces. I

faces. Ifaces. I

mmediately clean spilled brmmediately clean spilled br

mmediately clean spilled br

mmediately clean spilled brmmediately clean spilled br

e fluid will drip during bre fluid will drip during br

e fluid will drip during br

e fluid will drip during bre fluid will drip during br

akeake

ake

akeake

akeake

ake

akeake

Remove the hard line fitting, and quickly place
one of the rubber caps over the end of the hard
line, to control fluid loss during the installation.

Use needle-nose or small standard pliers to re­move the bracket holding the inboard end of
the stock brake line to the chassis bracket. Take
care to retain the clip for later use.

3541 Unit A, Lomita Boulevard, Torrance, CA 90505 [phone]
www.stoptech.com 8