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 (310) 325-4799
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
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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 (310) 325-4799 extension 105, or send an e-mail to
TION DISCLTION DISCL
TION DISCL
TION DISCLTION DISCL
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support@stoptech.comsupport@stoptech.com
support@stoptech.com.
support@stoptech.comsupport@stoptech.com
AIMERAIMER
AIMER
AIMERAIMER
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ote: Fote: F
N
ote: F
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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
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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 (310) 325-4799
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
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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.
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oise
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odification to Loodification to Lo
odification to Lo
odification to Loodification to Lo
TION DISCLTION DISCL
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all Jall J
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ointsoints
oints
ointsoints
AIMER (ContAIMER (Cont
AIMER (Cont
AIMER (ContAIMER (Cont
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rake rake
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rake
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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 (310) 325-4799 - extension 105, or you can e-mail directly to
support@stoptech.comsupport@stoptech.com
support@stoptech.com.
support@stoptech.comsupport@stoptech.com
NN
ote: Sote: S
N
ote: S
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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 -
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ech is not liable for vibrech is not liable for vibr
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ech is not liable for vibr
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ech is not liable for vibrech is not liable for vibr
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THIS IS IMPOR
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oper bed-in ofoper bed-in of
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3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 4
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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.
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otor and Potor and P
R
otor and P
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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
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afety Nafety N
S
afety N
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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 (310) 325-4799 - extension 105, or y ou can
e-mail directly to
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support@stoptech.comsupport@stoptech.com
support@stoptech.com.
support@stoptech.comsupport@stoptech.com
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
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
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ools and E
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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
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ers use alterers use alter
ers use alter
ers use alterers use alter
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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 (310) 325-4799
www.stoptech.com 6
Step 1Step 1
Step 1
Step 1Step 1
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aise aise
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aise
RR
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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.
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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
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WheelsWheels
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Wheels
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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
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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 (310) 325-4799
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
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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
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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 (310) 325-4799
www.stoptech.com 8
Step 3Step 3
Step 3
Step 3Step 3
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Remove the two stock caliper bolts, using a 21mm
wrench or socket, and retain the bolts for later
use.
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ote: F
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very tight. Ensure that you have a good pur-very tight. Ensure that you have a good pur-
very tight. Ensure that you have a good pur-
very tight. Ensure that you have a good pur-very tight. Ensure that you have a good purchase on the bolt head, and that you are in achase on the bolt head, and that you are in a
chase on the bolt head, and that you are in a
chase on the bolt head, and that you are in achase on the bolt head, and that you are in a
good position to turn the wrench or socket.good position to turn the wrench or socket.
good position to turn the wrench or socket.
good position to turn the wrench or socket.good position to turn the wrench or socket.
v
e S
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actoractor
actor
actoractor
tock Ctock C
tock C
tock Ctock C
y-installed caliper bolts may bey-installed caliper bolts may be
y-installed caliper bolts may be
y-installed caliper bolts may bey-installed caliper bolts may be
aliper & Raliper & R
aliper & R
aliper & Raliper & R
otorotor
otor
otorotor
Remove the stock rotor, by pulling it off of the
hub by hand.
Note: It may be necessary to strike the outerNote: It may be necessary to strike the outer
Note: It may be necessary to strike the outer
Note: It may be necessary to strike the outerNote: It may be necessary to strike the outer
edge of the rotor with a non-marring mallet,edge of the rotor with a non-marring mallet,
edge of the rotor with a non-marring mallet,
edge of the rotor with a non-marring mallet,edge of the rotor with a non-marring mallet,
if corrosion prevents the rotor from simplyif corrosion prevents the rotor from simply
if corrosion prevents the rotor from simply
if corrosion prevents the rotor from simplyif corrosion prevents the rotor from simply
being pulled off. If so, place a wheel bolt inbeing pulled off. If so, place a wheel bolt in
being pulled off. If so, place a wheel bolt in
being pulled off. If so, place a wheel bolt inbeing pulled off. If so, place a wheel bolt in
one of the holes first, to prevent the rotorone of the holes first, to prevent the rotor
one of the holes first, to prevent the rotor
one of the holes first, to prevent the rotorone of the holes first, to prevent the rotor
from falling when it comes loose.from falling when it comes loose.
from falling when it comes loose.
from falling when it comes loose.from falling when it comes loose.
Remove the caliper with the stock brake line attached. There may be some leakage from the
open end of the brake line, especially if the pads/
pistons on the caliper are retracted.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 9
SS
tep 4tep 4
S
tep 4
SS
tep 4tep 4
Install Caliper BracketInstall Caliper Bracket
Install Caliper Bracket
Install Caliper BracketInstall Caliper Bracket
Remov e the Jet nuts and washers from the caliper
mounting bracket, and put them aside for later
use.
Place a few drops of the supplied Loctite 262 on
the threads of each stock caliper bolt.
Tighten the caliper bracket bolts, using a 21mm
wrench or socket, then torque the bolts to
lb-ftlb-ft
lb-ft.
lb-ftlb-ft
125125
125
125125
Install the caliper bracket, using the stock caliper mounting bolts, with the bracket mounted
on the outboard side of the mounting lugs, and
the bolts inserted from the inboard side.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 10
SS
tep 5tep 5
S
tep 5
SS
tep 5tep 5
Install AeroRotor AssemblyInstall AeroRotor Assembly
Install AeroRotor Assembly
Install AeroRotor AssemblyInstall AeroRotor Assembly
AeroRotors
the rotors and pads, and will prevent the brakes fr om performing properly.
MUST MUST
MUST be cleaned with soap and water prior to installation. Not doing so will damage
MUST MUST
Ev en though the rotors may look clean, the rust
inhibitor is in place, and it must be removed.
Not cleaning the rotors will severely impact the
performance of your new brake system.
WW
arar
W
WW
ar
arar
ning: Dning: D
ning: D
ning: Dning: D
o not skip this step!o not skip this step!
o not skip this step!
o not skip this step!o not skip this step!
Install the hat and rotor assembly, ensuring that
the rotor is seated squarely on the hub face. If
necessary , clean the face of the hub, using a wir e
brush or similar means.
Place a couple of wheel nuts on the studs, to prevent the rotor from falling during brake installation.
NN
ote: Tote: T
N
ote: T
NN
ote: Tote: T
the rotors will severely decrease the cooling capacity of the system. The rotors are clearlythe rotors will severely decrease the cooling capacity of the system. The rotors are clearly
the rotors will severely decrease the cooling capacity of the system. The rotors are clearly
the rotors will severely decrease the cooling capacity of the system. The rotors are clearlythe rotors will severely decrease the cooling capacity of the system. The rotors are clearly
marmar
mar
marmar
inside the rotor should lean to the rear of the car on the top side of the rotor (see pages 13inside the rotor should lean to the rear of the car on the top side of the rotor (see pages 13
inside the rotor should lean to the rear of the car on the top side of the rotor (see pages 13
inside the rotor should lean to the rear of the car on the top side of the rotor (see pages 13inside the rotor should lean to the rear of the car on the top side of the rotor (see pages 13
and 14 for more-detailed images).and 14 for more-detailed images).
and 14 for more-detailed images).
and 14 for more-detailed images).and 14 for more-detailed images).
ake carake car
ake car
ake carake car
ked “Lked “L
ked “L
ked “Lked “L
e to ensure to ensur
e to ensur
e to ensure to ensur
” and “R” and “R
” and “R
” and “R” and “R
e that the re that the r
e that the r
e that the re that the r
” with or” with or
” with or
” with or” with or
otor assembly is on the corrotor assembly is on the corr
otor assembly is on the corr
otor assembly is on the corrotor assembly is on the corr
ange tags on the range tags on the r
ange tags on the r
ange tags on the range tags on the r
ect side of the carect side of the car
ect side of the car
ect side of the carect side of the car
otor hats. If the tags arotor hats. If the tags ar
otor hats. If the tags ar
otor hats. If the tags arotor hats. If the tags ar
, as r, as r
evev
, as r
, as r, as r
e not legible, the ve not legible, the v
e not legible, the v
e not legible, the ve not legible, the v
ersingersing
ev
ersing
evev
ersingersing
anesanes
anes
anesanes
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 11
SS
tep 5tep 5
S
tep 5
SS
tep 5tep 5
Install AeroRotor AssemblyInstall AeroRotor Assembly
Install AeroRotor Assembly
Install AeroRotor AssemblyInstall AeroRotor Assembly
It may be necessary to clearance the lower ball
joint slightly, to clear the inboard face of the
AeroRotor during full suspension travel. A coarse
file can remove the material, although a power
grinder is more efficient, if used properly .
Install the rotor , and check the pro ximity of the
lower ball joint to the inner rotor face. Turn the
wheel lock-to-lock, to determine how far around
the front and back edge needs to be clearanced.
(Cont (Cont
(Cont
(Cont (Cont
’’
d.)d.)
’
d.)
’’
d.)d.)
NN
ote: If only the lip arote: If only the lip ar
N
ote: If only the lip ar
NN
ote: If only the lip arote: If only the lip ar
removed, the structural integrity of the lowerremoved, the structural integrity of the lower
removed, the structural integrity of the lower
removed, the structural integrity of the lowerremoved, the structural integrity of the lower
ball joint will not be compromised. If you areball joint will not be compromised. If you are
ball joint will not be compromised. If you are
ball joint will not be compromised. If you areball joint will not be compromised. If you are
not comfortable making this modification, seeknot comfortable making this modification, seek
not comfortable making this modification, seek
not comfortable making this modification, seeknot comfortable making this modification, seek
the help of a qualified professional.the help of a qualified professional.
the help of a qualified professional.
the help of a qualified professional.the help of a qualified professional.
ound the outer ridge isound the outer ridge is
ound the outer ridge is
ound the outer ridge isound the outer ridge is
Remove ridge in this area
With the suspension at FULL DROOP, there
should be a clearance of 3.5 - 4.8mm (1/8 - 3/16)
between the inner face of the rotor and the outer
diameter of the lower ball joint.
3.5 - 4.8mm
at full droop
Remov e the lip which protrudes around the outer
edge of the ball joint (the approximate area is
shown in the photograph to the left).
Ridge Width
3541 Unit A, Lomita Boulevard, T orrance, CA 90505 (310) 325-4799
www.stoptech.com 12
Outboard SideOutboard Side
Outboard Side
Outboard SideOutboard Side
Left-Side Rotor
Right-Side Rotor
DD
D
DD
rivriv
riv
rivriv
erer
er
erer
’’
’
’’
s Lefts Left
s Left
s Lefts Left
Outboard SideOutboard Side
Outboard Side
Outboard SideOutboard Side
DD
rivriv
erer
’’
riv
rivriv
s Rights Right
er
’
s Right
erer
’’
s Rights Right
D
DD
3541 Unit A, Lomita Boulevard, T orrance, CA 90505 (310) 325-4799
www.stoptech.com 13
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 14
CC
aliper Component Ialiper Component I
C
aliper Component I
CC
aliper Component Ialiper Component I
dentificationdentification
dentification
dentificationdentification
Use a light film of anti-seize on the bridge
bolt shafts and threads
The ST-40 original equipment caliper uses a common P orsche-style pad.
The Friction Materials S tandar ds I nstitute (FMSI) number for the pad backing plate is D372.
For further pad interchange infor mation, please see the FA Q section of the StopTech website at:
www.stoptech.com
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 15
SS
tep 6tep 6
S
tep 6
SS
tep 6tep 6
II
nstall Cnstall C
I
nstall C
II
nstall Cnstall C
NN
ote: The images in this section may not be of the vote: The images in this section may not be of the v
N
ote: The images in this section may not be of the v
NN
ote: The images in this section may not be of the vote: The images in this section may not be of the v
representation of the correct installation.representation of the correct installation.
representation of the correct installation.
representation of the correct installation.representation of the correct installation.
Determine the left- and right-hand side calipers. They are clearly mar ked on the box, but as a check,
the bleed screws are always positioned at the top of the caliper . I f installing a four-wheel kit, with ST 40 calipers on the front and rear of the vehicle, be sur e that the correct caliper is on each cor ner . The
calipers with the smaller piston sizes go on the rear of the vehicle.
aliper and Paliper and P
aliper and P
aliper and Paliper and P
adsads
ads
adsads
ehicle noted, but theehicle noted, but the
ehicle noted, but the
ehicle noted, but theehicle noted, but the
Remov e the two bolts holding the caliper bridge
in place, using a 5mm Allen wrench.
Bridge Bolts
Remov e the caliper bridge, taking note of the direction in which it is installed, and the correct
location of the pad-retaining wire clip, which
typically , but not always, remains attached to the
bridge.
y givy giv
y giv
y givy giv
e a pre a pr
e a pr
e a pre a pr
operoper
oper
operoper
In order to stiffen the caliper , the bridge must fit
snugly, and the bolts may be tight when removing them. Keep turning the bolts gently, with
pressure applied in the direction of removal.
After removing the bolts, it may be necessary to
tap the bridge out from the inside of the caliper ,
using a mallet or similar tool (the handle of a
tool works well for this). With use, the bridge
and bolts will become easier to remove and insert.
NN
ote: When the pad-rote: When the pad-r
N
ote: When the pad-r
NN
ote: When the pad-rote: When the pad-r
correctly, its welded joint should not be vis-correctly, its welded joint should not be vis-
correctly, its welded joint should not be vis-
correctly, its welded joint should not be vis-correctly, its welded joint should not be visible thrible thr
ible thr
ible thrible thr
ough the bridgeough the bridge
ough the bridge
ough the bridgeough the bridge
etaining clip is orientedetaining clip is oriented
etaining clip is oriented
etaining clip is orientedetaining clip is oriented
’’
s air-scoop opening.s air-scoop opening.
’
s air-scoop opening.
’’
s air-scoop opening.s air-scoop opening.
3541 Unit A, Lomita Boulevard, T orrance, CA 90505 (310) 325-4799
www.stoptech.com 16
SS
tep 6tep 6
S
tep 6
SS
tep 6tep 6
II
nstall Cnstall C
I
nstall C
II
nstall Cnstall C
Install the caliper onto the adapter bracket, orienting it so that the bleed screws are positioned
on the top side of the caliper .
Take care to ensur e that the caliper is square and
evenly started on both studs. It may be necessary
to use a mallet to gently tap the caliper into position.
Install a Jet nut onto each stud, with a 12mm
washer under each nut. Tighten the Jet nuts to
40 lb-ft 40 lb-ft
40 lb-ft o f torque, using a 1/2” wrench or socket.
40 lb-ft 40 lb-ft
(Cont (Cont
(Cont
(Cont (Cont
’’
d.)d.)
’
d.)
’’
d.)d.)
aliper and Paliper and P
aliper and P
aliper and Paliper and P
adsads
ads
adsads
Apply a light film of anti-seize compound onto
the bridge bolt shafts and threads.
Slide the brake pads into position within the caliper , taking care to ensure that the friction side of
each pad is facing the rotor .
(Y(Y
es, thees, the
(Y
es, the
(Y(Y
es, thees, the
yy
’’
vv
e been installed backware been installed backwar
y
’
v
e been installed backwar
yy
’’
vv
e been installed backware been installed backwar
d beford befor
d befor
d beford befor
e!)e!)
e!)
e!)e!)
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 17
SS
tep 6tep 6
S
tep 6
SS
tep 6tep 6
II
nstall Cnstall C
I
nstall C
II
nstall Cnstall C
Install the bridge by sliding it into position, and
rocking it until one of the bolt holes lines up.
T ake car e to ensure that the bridge is slid straight
and parallel into the caliper body opening.
NN
N
NN
be positioned so that the air-scoop opening isbe positioned so that the air-scoop opening is
be positioned so that the air-scoop opening is
be positioned so that the air-scoop opening isbe positioned so that the air-scoop opening is
located in the bottom half of the bridge.located in the bottom half of the bridge.
located in the bottom half of the bridge.
located in the bottom half of the bridge.located in the bottom half of the bridge.
(Cont (Cont
(Cont
(Cont (Cont
ote: The bridge is dirote: The bridge is dir
ote: The bridge is dir
ote: The bridge is dirote: The bridge is dir
’’
d.)d.)
’
d.)
’’
d.)d.)
aliper and Paliper and P
aliper and P
aliper and Paliper and P
adsads
ads
adsads
ectional, and shouldectional, and should
ectional, and should
ectional, and shouldectional, and should
Insert the first bridge bolt, from the outside of
the caliper , and start the first few threads, using a
5mm Allen wrench.
Start the second bolt, and apply pressure to the
bridge, using the palm of your hand, or by gently tapping the bridge with a mallet, until the
bolt engages in the hole. Start the first few threads,
using a 5mm Allen wrench.
Double-check the orientation of the bridge, to
ensure that the air-scoop opening is located in
the bottom half of the bridge.
apprappr
oo
Torque each bolt to
using a 5mm Allen wrench. Do not use a torque
wrench, as the use of anti-seize compound will
cause a false reading. Do not over-torque the
bridge bolts - snug is tight enough.
WW
arar
ning: Dning: D
W
ar
ning: D
WW
arar
ning: Dning: D
into place. Tinto place. T
into place. T
into place. Tinto place. T
o not hammer the bridge boltso not hammer the bridge bolts
o not hammer the bridge bolts
o not hammer the bridge boltso not hammer the bridge bolts
ap the bridge, not the bolts!ap the bridge, not the bolts!
ap the bridge, not the bolts!
ap the bridge, not the bolts!ap the bridge, not the bolts!
appr
apprappr
ximately 8-10 lb-ftximately 8-10 lb-ft
o
ximately 8-10 lb-ft,
oo
ximately 8-10 lb-ftximately 8-10 lb-ft
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 18
SS
tep 7tep 7
S
tep 7
SS
tep 7tep 7
AA
ttach Sttach S
A
ttach S
AA
ttach Sttach S
Install the caliper end of the stainless steel brake
line by first placing a copper crush washer on
either side of the banjo fitting, then inserting the
banjo bolt into the fitting.
tainless Stainless S
tainless S
tainless Stainless S
teel Bteel B
teel B
teel Bteel B
rake Linerake Line
rake Line
rake Linerake Line
Copper
Insert the banjo bolt into the caliper , angling the
banjo fitting so that it is leaning slightly forward.
Torque the banjo bolt to
ftft
ft, using a 14mm wrench or socket.
ftft
NN
ote: Dote: D
N
ote: D
NN
ote: Dote: D
tightening the bolt can strip the aluminumtightening the bolt can strip the aluminum
tightening the bolt can strip the aluminum
tightening the bolt can strip the aluminumtightening the bolt can strip the aluminum
threads, causing irreparable damage to thethreads, causing irreparable damage to the
threads, causing irreparable damage to the
threads, causing irreparable damage to thethreads, causing irreparable damage to the
calipercaliper
caliper
calipercaliper
o not use a toro not use a tor
o not use a tor
o not use a toro not use a tor
..
.
..
apprappr
appr
apprappr
que wrque wr
que wr
que wrque wr
Banjo bolt
oo
ximately 14 lb-ximately 14 lb-
o
ximately 14 lb-
oo
ximately 14 lb-ximately 14 lb-
ench, as oench, as o
ench, as o
ench, as oench, as o
vv
v
vv
er-er-
er-
er-er-
Remove the rubber cap from the hard line, and
screw the stainless steel brake line onto the hard
line fitting by hand for a few turns.
Use an 11/16” wrench to hold the stainless line
fitting, while using a 13mm flare wrench to
tighten the hard line fitting.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 19
SS
tep 7tep 7
S
tep 7
SS
tep 7tep 7
AA
A
AA
Reinstall the line-retaining spring clip, to secure
the stainless brake line in place.
T ake car e to ensure that the prongs on the spring
clip are seated within the recesses on the brake
line fitting, then use a mallet to gently tap the
spring clip into place.
After securing the brake line, turn the wheels lockto-lock to ensure that the line is not binding or
touching any moving part of the suspension.
Adjust the line, if necessary, by re-clocking the
banjo bolt on the caliper, or by reorienting the
inboard line fitting.
(Cont (Cont
(Cont
(Cont (Cont
ttach Sttach S
ttach S
ttach Sttach S
’’
d.)d.)
’
d.)
’’
d.)d.)
tainless Stainless S
tainless S
tainless Stainless S
teel Bteel B
teel B
teel Bteel B
rake Linerake Line
rake Line
rake Linerake Line
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 20
SS
tep 8tep 8
S
tep 8
SS
tep 8tep 8
Bleed BrakesBleed Brakes
Bleed Brakes
Bleed BrakesBleed Brakes
Complete the installation on both sides of the vehicle before bleeding the system.
NN
ote: The calipers and lines will need to fill with fluid, quickly drote: The calipers and lines will need to fill with fluid, quickly dr
N
ote: The calipers and lines will need to fill with fluid, quickly dr
NN
ote: The calipers and lines will need to fill with fluid, quickly drote: The calipers and lines will need to fill with fluid, quickly dr
rr
esereser
vv
oiroir
. K. K
r
eser
v
oir
esereser
vv
rr
the master cylinder rthe master cylinder r
the master cylinder r
the master cylinder rthe master cylinder r
system needing to be serviced by a certified brake technician.system needing to be serviced by a certified brake technician.
system needing to be serviced by a certified brake technician.
system needing to be serviced by a certified brake technician.system needing to be serviced by a certified brake technician.
Bleed the brake system, using an 11mm box wrench, to loosen the bleed scr ews. The sequence for
bleeding the brakes should be:
Though a torque wrench is not typically used on bleed screws, as a reference, the torque for bleed
screws should be
oiroir
eep a close watch on the fluid leveep a close watch on the fluid lev
. K
eep a close watch on the fluid lev
. K. K
eep a close watch on the fluid leveep a close watch on the fluid lev
esereser
vv
oir to roir to r
eser
v
oir to r
esereser
vv
oir to roir to r
1. Right outboard bleed screw
2. Right inboard bleed screw
3. Left outboard bleed screw
4. Left inboard bleed screw
approximately 100-140 lb-INCHapproximately 100-140 lb-INCH
approximately 100-140 lb-INCH.
approximately 100-140 lb-INCHapproximately 100-140 lb-INCH
un drun dr
un dr
un drun dr
el when initially bleeding the system. Del when initially bleeding the system. D
el when initially bleeding the system. D
el when initially bleeding the system. Del when initially bleeding the system. D
yy
, and to dr, and to dr
y
, and to dr
yy
, and to dr, and to dr
aw in airaw in air
aw in air
aw in airaw in air
. D. D
. D
. D. D
aining the master cylinderaining the master cylinder
aining the master cylinder
aining the master cylinderaining the master cylinder
o not alloo not allo
o not allo
o not alloo not allo
oing so may roing so may r
oing so may r
oing so may roing so may r
esult in the bresult in the br
esult in the br
esult in the bresult in the br
ww
w
ww
ake
ake
ake
akeake
After initially bleeding the system, gently tap the caliper body with a mallet to dislodge any small
air bubbles, then re-bleed the brakes.
After bleeding, apply constant pressure to the brake pedal, and check all connections - including
bleed screws, and both ends of the brake line - for leaks.
WW
arar
ning: Bning: B
W
ar
ning: B
WW
arar
ning: Bning: B
fluid frfluid fr
fluid fr
fluid frfluid fr
harsh chemicals, prolonged exposure will damage the finish.harsh chemicals, prolonged exposure will damage the finish.
harsh chemicals, prolonged exposure will damage the finish.
harsh chemicals, prolonged exposure will damage the finish.harsh chemicals, prolonged exposure will damage the finish.
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
om any painted surom any painted sur
om any painted sur
om any painted surom any painted sur
face, including the caliperface, including the caliper
face, including the caliper
face, including the caliperface, including the caliper
faces. Ifaces. I
faces. I
faces. Ifaces. I
. Though caliper paint is designed to r. Though caliper paint is designed to r
. Though caliper paint is designed to r
. Though caliper paint is designed to r. Though caliper paint is designed to r
mmediately clean spilled brmmediately clean spilled br
mmediately clean spilled br
mmediately clean spilled brmmediately clean spilled br
akeake
ake
akeake
esistesist
esist
esistesist
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 21
SS
tep 9tep 9
S
tep 9
SS
tep 9tep 9
RR
einstall einstall
R
einstall
RR
einstall einstall
It is very important to check the wheel-to-caliper clearance before installing wheels!
NN
ote: Sote: S
N
ote: S
NN
ote: Sote: S
ww
eight is on the outboareight is on the outboar
w
eight is on the outboar
ww
eight is on the outboareight is on the outboar
sarsar
yy
, note the w, note the w
sar
y
, note the w
sarsar
yy
, note the w, note the w
inboarinboar
inboar
inboarinboar
positions on all four wheels, and also on the spare, if it is full-sized.positions on all four wheels, and also on the spare, if it is full-sized.
positions on all four wheels, and also on the spare, if it is full-sized.
positions on all four wheels, and also on the spare, if it is full-sized.positions on all four wheels, and also on the spare, if it is full-sized.
Reinstall the wheels, and torque the lug nuts to your wheel manufacturer’s specifications. I t may be
necessary to snug the bolts before lowering the v ehicle, and to then torque the wheels when the car is
on the ground. Alternatively, an assistant may depress the brake pedal while you tighten the wheel
nuts to the proper torque setting.
Carefully test-driv e the vehicle in a safe ar ea, at low speed, to ensure that all components ar e working
correctly. Then follo w the pad and rotor bed-in procedur e on the follo wing pages.
WheelsWheels
Wheels
WheelsWheels
ome wheels arome wheels ar
ome wheels ar
ome wheels arome wheels ar
eight and location of the lead, and place a new piece of the same weight and location of the lead, and place a new piece of the same w
eight and location of the lead, and place a new piece of the same w
eight and location of the lead, and place a new piece of the same weight and location of the lead, and place a new piece of the same w
d or outboar
d or outboar
d or outboar
d or outboard or outboar
e balanced on the inside, with adhesive balanced on the inside, with adhesiv
e balanced on the inside, with adhesiv
e balanced on the inside, with adhesive balanced on the inside, with adhesiv
d edge, behind the spokes, it may interd edge, behind the spokes, it may inter
d edge, behind the spokes, it may inter
d edge, behind the spokes, it may interd edge, behind the spokes, it may inter
d, to clear the caliperd, to clear the caliper
d, to clear the caliper
d, to clear the caliperd, to clear the caliper
. If y. If y
. If y
. If y. If y
ou rou r
otate the tirotate the tir
ou r
otate the tir
ou rou r
otate the tirotate the tir
e-backed lead we-backed lead w
e-backed lead w
e-backed lead we-backed lead w
ferfer
e with the calipere with the caliper
fer
e with the caliper
ferfer
e with the calipere with the caliper
es res r
es r
es res r
egularlyegularly
egularly
egularlyegularly
, check the lead w, check the lead w
, check the lead w
, check the lead w, check the lead w
eights. If theeights. If the
eights. If the
eights. If theeights. If the
. If neces-. If neces-
. If neces-
. If neces-. If neces-
eight fureight fur
eight fur
eight fureight fur
therther
ther
therther
eighteight
eight
eighteight
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 22
AeroRotor Installation & Bed-in Procedure
READ READ
READ
READ READ
FF
AILAIL
URE URE
F
AIL
URE
FF
AILAIL
URE URE
WILL CAWILL CA
WILL CA
WILL CAWILL CA
KEEP KEEP
KEEP
KEEP KEEP
The majority of brake system problems are due to improper installation and/or bed-in of the rotors
and pads. By reading and understanding the following, you will avoid the most common causes of
poor brake performance and vibration. FAILURE TO READ AND UNDERSTAND THIS MAY
CAUSE SERIOUS P ERMANENT DAMAGE T O YOUR NEW R OTORS.
WW
W
WW
StopTech coats non-plated AeroR otors with a water-soluble, environmentally friendly rust inhibitor
that MUST be cleaned off before use. A non-plated rotor looks like bare metal, while plated rotors
are bright silver in color , and do not need to be washed. E ven though y ou may not see a change in the
rotor color, if the rotor is not rusty, the rust inhibitor is there. Use soap and water, NOT BRAKE
CLEANER to wash the rotors. A small piece of Scotchbrite works well for scrubbing. When cleaned
and rinsed properly , the surface of the rotor may show a light rust color, which is normal.
TT
O READ, UNDERSTO READ, UNDERST
T
O READ, UNDERST
TT
O READ, UNDERSTO READ, UNDERST
USE PUSE P
USE P
USE PUSE P
THE SYSTEM FRTHE SYSTEM FR
THE SYSTEM FR
THE SYSTEM FRTHE SYSTEM FR
ash Nash N
ash N
ash Nash N
ERMANENT DAMAERMANENT DAMA
ERMANENT DAMA
ERMANENT DAMAERMANENT DAMA
on-Pon-P
on-P
on-Pon-P
AND AND
AND
AND AND
WW
W
WW
OM OM
OM
OM OM
lated Alated A
lated A
lated Alated A
AA
A
AA
THIS NOTHIS NO
THIS NO
THIS NOTHIS NO
AND AND FOLLAND AND FOLL
AND AND FOLL
AND AND FOLLAND AND FOLL
GE GE
TT
O O
T
TT
erer
er
erer
YY
O
Y
O O
YY
T ITT IT
T IT
T ITT IT
oRoR
oR
oRoR
GE
GE GE
WW
ORKING AORKING A
W
ORKING A
WW
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TER beforTER befor
OUR BRAKE ROUR BRAKE R
OUR BRAKE R
OUR BRAKE ROUR BRAKE R
e installation.e installation.
e installation.
e installation.e installation.
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W W
THESE PRTHESE PR
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S FULL CAPS FULL CAP
S FULL CAP
S FULL CAPS FULL CAP
otors with SOotors with SO
otors with SO
otors with SOotors with SO
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ORS, AND ORS, AND
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ORS, AND
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OCEDURESOCEDURES
OCEDURES
OCEDURESOCEDURES
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AP
APAP
Bed-in yBed-in y
Bed-in y
Bed-in yBed-in y
serser
ving the prving the pr
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Bed-in of rotors and pads is critical to the optimum performance of your new brakes. When beddingin new parts, you are not only heat-cycling the pads, you are also depositing a layer of pad material
onto the rotor face. If not bedded-in properly , an unev en layer of pad material will be deposited onto
the rotor , causing vibration.
to uneven pad deposition.to uneven pad deposition.
to uneven pad deposition.
to uneven pad deposition.to uneven pad deposition.
NN
ote: Pote: P
N
ote: P
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ote: Pote: P
rotor faces, BEFORE starting the bed-in procedure. Do not use brakes aggressively until therotor faces, BEFORE starting the bed-in procedure. Do not use brakes aggressively until the
rotor faces, BEFORE starting the bed-in procedure. Do not use brakes aggressively until the
rotor faces, BEFORE starting the bed-in procedure. Do not use brakes aggressively until therotor faces, BEFORE starting the bed-in procedure. Do not use brakes aggressively until the
plating is worn off, typically after several miles of driving.plating is worn off, typically after several miles of driving.
plating is worn off, typically after several miles of driving.
plating is worn off, typically after several miles of driving.plating is worn off, typically after several miles of driving.
Typically, a heavy-braking street driv er will experience approximately 1 to 1.1G’s of deceleration. A t
this rate, the ABS will be activated on such equipped vehicles. A moderate braking effort is needed to
properly bed-in rotors and pads. If ABS intervention or lockup were represented as 100% brake
effort, a stopping force of approximately 70-80%, just short of ABS intervention or lockup, is a
general estimate of the pedal effort you are trying to achieve.
wing page.wing page.
wing page.
wing page.wing page.
lated rlated r
lated r
lated rlated r
our new pads and rour new pads and r
our new pads and r
our new pads and rour new pads and r
ocedurocedur
ocedur
ocedurocedur
VV
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otors must be drivotors must be driv
otors must be driv
otors must be drivotors must be driv
tually evtually ev
tually ev
tually evtually ev
en with gentle bren with gentle br
en with gentle br
en with gentle bren with gentle br
e described on this and thee described on this and the
e described on this and the
e described on this and thee described on this and the
erer
y instance of a “y instance of a “
er
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otors botors b
otors b
otors botors b
aking, until the CAD plating is woraking, until the CAD plating is wor
aking, until the CAD plating is wor
aking, until the CAD plating is woraking, until the CAD plating is wor
y cary car
y car
y cary car
warpedwarped
warped
warpedwarped
efully ob-efully ob-
efully ob-
efully ob-efully ob-
” r” r
otor is attributedotor is attributed
” r
otor is attributed
” r” r
otor is attributedotor is attributed
n off of then off of the
n off of the
n off of then off of the
(Continued on next page)(Continued on next page)
(Continued on next page)
(Continued on next page)(Continued on next page)
3541 Unit A, Lomita Boulevard, T orrance, CA 90505 (310) 325-4799
www.stoptech.com 23
RR
otor and Potor and P
R
otor and P
RR
otor and Potor and P
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After completing the installation, make a series of 10 stops from 60 to 5-10 MPH. At the end of each
stop, immediately accelerate to 60 again for the next stop. Run all stops in one cycle.
During the 60 to 5-10 MPH cycle of stops, the exact speed is not critical. Accelerate to approximately
60, then begin braking. As you approach 5-10 MPH, it is not necessary to watch the speedometer.
Keep your ey es on the road, and approximate y our speed at the end of each stop. DO NOT COME
TO A COMPLETE STOP, WHILE LEAVING YOUR FOOT ON THE BRAKE PEDAL, AS YOU
MA Y IMPRINT PAD MATERIAL ONT O THE R O T OR, CA USING A VIBRATION.
If racing or higher-performance pads are being used, add four stops from 80 to 5-10 MPH, andIf racing or higher-performance pads are being used, add four stops from 80 to 5-10 MPH, and
If racing or higher-performance pads are being used, add four stops from 80 to 5-10 MPH, and
If racing or higher-performance pads are being used, add four stops from 80 to 5-10 MPH, andIf racing or higher-performance pads are being used, add four stops from 80 to 5-10 MPH, and
if full race pads are being used, add four stops from 100 to 5-10 MPH.if full race pads are being used, add four stops from 100 to 5-10 MPH.
if full race pads are being used, add four stops from 100 to 5-10 MPH.
if full race pads are being used, add four stops from 100 to 5-10 MPH.if full race pads are being used, add four stops from 100 to 5-10 MPH.
There are sev eral indicators to look for while bedding-in the system:
On the 8th or 9th stop, there should be a distinct smell from the brakes. Smoke may also be evident
after several stops.
Also on the 8th or 9th stop, some friction material will experience “gr een fade.” This is a slight fading
of the brakes. The fade will stabilize, but will not completely go away until the brakes have cooled.
edding-in of pads should not be done in poor wedding-in of pads should not be done in poor w
edding-in of pads should not be done in poor w
edding-in of pads should not be done in poor wedding-in of pads should not be done in poor w
ad Bed-in (Contad Bed-in (Cont
ad Bed-in (Cont
ad Bed-in (Contad Bed-in (Cont
’’
d.)d.)
’
d.)
’’
d.)d.)
eather conditions, nor on weather conditions, nor on w
eather conditions, nor on w
eather conditions, nor on weather conditions, nor on w
et ret r
et r
et ret r
oads.oads.
oads.
oads.oads.
After the bed-in cycle is finished, there will be a blue tint on the rotor, with a light gray film on the
rotor face. The blue tint indicates that the rotor has r eached the proper bed-in temperatur e, and the
gray film is pad material starting to transfer onto the rotor face. This is nor mal!
After the first bed-in cyAfter the first bed-in cy
After the first bed-in cy
After the first bed-in cyAfter the first bed-in cy
their best capacitytheir best capacity
their best capacity
their best capacitytheir best capacity
brakes rbrakes r
brakes r
brakes rbrakes r
down.down.
down.
down.down.
SS
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limit, do so in a safe area, away from traffic, and at your own risk.limit, do so in a safe area, away from traffic, and at your own risk.
limit, do so in a safe area, away from traffic, and at your own risk.
limit, do so in a safe area, away from traffic, and at your own risk.limit, do so in a safe area, away from traffic, and at your own risk.
After the final stop of each cycle, driv e as much as possible without using the brakes, to cool off the
system. Ideally, the brakes should be allowed to cool to ambient temperature before using them
again.
DO NODO NO
DO NO
DO NODO NO
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OUR FOO
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OUR FOOOUR FOO
RR
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eally stareally star
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ech does not endorse speeding on public rech does not endorse speeding on public r
ech does not endorse speeding on public r
ech does not endorse speeding on public rech does not endorse speeding on public r
T CT C
OME OME
T C
OME
T CT C
OME OME
T ON T ON
T ON
T ON T ON
OR, CAOR, CA
OR, CA
OR, CAOR, CA
USING A USING A
USING A
USING A USING A
. A second or thir. A second or thir
. A second or thir
. A second or thir. A second or thir
t to “t to “
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O A CO A C
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THE BRAKE PTHE BRAKE P
THE BRAKE P
THE BRAKE PTHE BRAKE P
cle shocle sho
cle sho
cle shocle sho
come in.” A “come in.” A “
come in.” A “
come in.” A “come in.” A “
OMPLETE STOMPLETE ST
OMPLETE ST
OMPLETE STOMPLETE ST
VIBRAVIBRA
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VIBRAVIBRA
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EDAL. P
EDAL. PEDAL. P
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e, the brakes will still not be operating ate, the brakes will still not be operating at
e, the brakes will still not be operating at
e, the brakes will still not be operating ate, the brakes will still not be operating at
cle is typically necessarcle is typically necessar
cle is typically necessar
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” is a series of stops, follo” is a series of stops, follo
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THE SYSTEM IS HOTHE SYSTEM IS HO
THE SYSTEM IS HO
THE SYSTEM IS HOTHE SYSTEM IS HO
AD MAAD MA
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TERIAL MA
TERIAL MATERIAL MA
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WHILE LEAWHILE LEA
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WHILE LEAWHILE LEA
e thee the
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If you have any questions about rotor and pad bed-in, any aspect of your StopTech brake kit, or
brakes in general, please contact the StopTech Customer Service Department at (310) 325-4799 extension 105, or e-mail us at support@stoptech.com
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 24
Thank yThank y
Thank y
Thank yThank y
We realize that you had a choice when selecting a big brake upgrade for your vehicle,
and we know that y o u’ll be happy with our system.
We proudly support our fine products. For any assistance or
questions, please contact our Customer Service Department
ou for selecting Sou for selecting S
ou for selecting S
ou for selecting Sou for selecting S
at
(310) 325-4799 - extension 105
or e-mail us at
support@stoptech.comsupport@stoptech.com
support@stoptech.com
support@stoptech.comsupport@stoptech.com
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