InstallaInstalla
Installa
InstallaInstalla
2000+ Lincoln LS2000+ Lincoln LS
2000+ Lincoln LS
2000+ Lincoln LS2000+ Lincoln LS
tion Instrtion Instr
tion Instr
tion Instrtion Instr
uctionsuctions
uctions
uctionsuctions
355mm F355mm F
355mm F
355mm F355mm F
Big BrBig Br
Big Br
Big BrBig Br
STST
ST
STST
98-530-1470 Rev. A 03-18-05
akak
ak
akak
-40 Caliper-40 Caliper
-40 Caliper
-40 Caliper-40 Caliper
e Upge Upg
e Upg
e Upge Upg
rr
ontont
r
ont
rr
ontont
rr
adeade
r
ade
rr
adeade
Caliper Brackets
CC
OMPONENT IDENTIFICAOMPONENT IDENTIFICA
C
OMPONENT IDENTIFICA
CC
OMPONENT IDENTIFICAOMPONENT IDENTIFICA
AeroRotor and Hat Assemblies
TIONTION
TION
TIONTION
High-Performance
Street P ads
Calipers
Stainless Steel Braided Lines and Hardware
Lincoln LS FLincoln LS F
Lincoln LS F
Lincoln LS FLincoln LS F
(This is a representative photograph. The actual components in
your kit may appear slightly different.)
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 2
rr
ont Bont B
r
ont B
rr
ont Bont B
ig Big B
ig B
ig Big B
rake Krake K
rake K
rake Krake K
itit
it
itit
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
link at the bottom of the home page. BEFORE printing out a copy of the wheel fitment drawing for
your vehicle, click on the ‘How do I use the charts?’ link at the top of the page, and review the
instructions carefully, to ensure that y ou hav e a full understanding of how to accurately measur e the
critical wheel clearances. Only then should you click on the link for your vehicle, and print out the
appropriate wheel fitment drawing, to use as a measurement template.
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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.stoptech.com.stoptech.com
www
.stoptech.com, and click on the ‘Wheel Fitment Charts’
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.stoptech.com.stoptech.com
support@stoptech.comsupport@stoptech.com
support@stoptech.com.
support@stoptech.comsupport@stoptech.com
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 (310) 325-4799
www.stoptech.com 3
APPLICAAPPLICA
APPLICA
APPLICAAPPLICA
PP
erer
manent Rmanent R
P
er
manent R
PP
erer
manent Rmanent R
The dust shield must be permanently remo ved from both front wheels of the v ehicle, to accommodate
the AeroRotors. This involves drilling out or chiseling off the rivets on each shield. These operations can be dangerous, and serious injury can occur . F or any one who is not competent or comfortable performing these operations, StopTech firmly recommends seeking the services of a trained
professional.
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.
oiseoise
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oiseoise
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TION DISCLTION DISCL
TION DISCL
TION DISCLTION DISCL
ust Sust S
ust S
ust Sust S
hieldhield
hield
hieldhield
AIMER (ContAIMER (Cont
AIMER (Cont
AIMER (ContAIMER (Cont
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’
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’’
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 (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
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 sponsorated nor affiliated with, nor sponsor
ated nor affiliated with, nor sponsor
ated nor affiliated with, nor sponsorated nor affiliated with, nor sponsor
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
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ties of their rties of their r
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operoper
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ANT!ANT!
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ations caused by eations caused by e
ations caused by e
ations caused by eations caused by e
espectivespectiv
espectiv
espectivespectiv
ed bed b
ed b
ed bed b
y Fy F
y F
y Fy F
oror
or
oror
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wners. Swners. S
e o
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d.d.
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eme usage or impreme usage or impr
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eme usage or impreme usage or impr
topTtopT
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ech LLech LL
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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 (310) 325-4799
www.stoptech.com 4
II
mpormpor
I
mpor
II
mpormpor
tant Ntant N
tant N
tant Ntant N
oticesotices
otices
oticesotices
Wheel FWheel F
Wheel F
Wheel FWheel F
Do not assume that your wheels will fit. An outline drawing of your StopTech Big Brake kit is
available on our website at
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 IN-
ST 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 . E v en 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 . Pr oper bedin will greatly minimize such problems. F ollow, as closely as possible, the bed-in procedure detailed
later in this manual, or refer to the StopTech website at
itmentitment
itment
itmentitment
ad Bed-inad Bed-in
ad Bed-in
ad Bed-inad Bed-in
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www
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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 r ecommended that a
trained, experienced mechanic, with proper equipment, install the Big Brake Kit supplied by StopTech
LLC. S topT ech LL C assumes no liability , expressed 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 ar e subject to stresses and conditions outside of normal use, wear and tear. All equipment sold or provided by StopTech LLC is sold WITHOUT WARRANTY, 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 mal-performance after installation. Under no cir cumstances is S topTech 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 Service Department on (310) 325-4799 - extension 105, or you can email directly to
oticeotice
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oticeotice
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arrantyarranty
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arranty
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arrantyarranty
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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
Lincoln LS FLincoln LS F
Lincoln LS F
Lincoln LS FLincoln LS F
NN
ote: Iote: I
N
ote: I
NN
ote: Iote: I
bed-in procedure, before starting the installation.bed-in procedure, before starting the installation.
bed-in procedure, before starting the installation.
bed-in procedure, before starting the installation.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 the 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 M12 x 1.75 hex-head bolts (caliper bolts)
2 pair of 12mm washers
1 capsule of Loctite 262
1 pair of stainless steel brake lines
1 pair of chassis brackets
1 pair of banjo bolts
2 pair of copper crush washers
1 pair of rubber end caps
3 pair of high-temperature cable ties
3 pair of rubber tubing segments
t is import is impor
t is impor
t is import is impor
tant to rtant to r
tant to r
tant to rtant to r
ead and understand this ENTIRE installation manual, including theead and understand this ENTIRE installation manual, including the
ead and understand this ENTIRE installation manual, including the
ead and understand this ENTIRE installation manual, including theead and understand this ENTIRE installation manual, including the
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ont Axle K
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3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 6
Lincoln LS FLincoln LS F
Lincoln LS F
Lincoln LS FLincoln LS F
TT
ools and Eools and E
T
ools and E
TT
ools and Eools and E
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. Occasionally, however,
manufacturers may use an alternate fastener, so it’s advisable to check that each tool correctly fits
the fastener before loosening or tightening it. The following tools and equipment will be needed:
17mm socket
17mm wrench
15mm wrench or socket (1/2” drive suggested)
14mm wrench or socket (in some cases, 9/16” may be required)
13mm flare wrench
11mm box wrench (in addition, an 11mm flare wrench is also recommended)
10mm wrench or socket
1/2” socket wrench (3/8” drive suggested)
5mm Allen (hex) wrench
Needle-nose pliers, or a flat-blade screwdriver
Diagonal cutters
Power drill, or chisel and hammer
Safety glasses and work gloves for the metal drilling/chiseling process
To rque wrenches capable of 10-85 lb-ft settings
Small drip tray or several rags
Small funnel or suitable means of filling master cylinder reservoir
Anti-seize compound
Brake bleed bottle
1 pair of jack stands or other means of supporting vehicle
Plastic or non-marring mallet
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.
quipment Rquipment R
quipment R
quipment Rquipment R
equirequir
equir
equirequir
eded
ed
eded
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it (Contit (Cont
it (Cont
it (Contit (Cont
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’
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3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 7
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tep 1
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ote: All photographs show a left-hand side installation, unless otherwise noted. Some ofote: All photographs show a left-hand side installation, unless otherwise noted. Some of
N
ote: All photographs show a left-hand side installation, unless otherwise noted. Some of
ote: All photographs show a left-hand side installation, unless otherwise noted. Some ofote: All photographs show a left-hand side installation, unless otherwise noted. Some of
NN
the images in this manual may not be of the vehicle noted, but they give a proper representa-the images in this manual may not be of the vehicle noted, but they give a proper representa-
the images in this manual may not be of the vehicle noted, but they give a proper representa-
the images in this manual may not be of the vehicle noted, but they give a proper representa-the images in this manual may not be of the vehicle noted, but they give a proper representation of the correct installation.tion of the correct installation.
tion of the correct installation.
tion of the correct installation.tion of the correct installation.
A level, stable and clean surface, suitable for supporting the vehicle on jack-stands, should be
used for the installation.
WW
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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 car.
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
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e any ve any v
e any v
e any ve any v
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WheelsWheels
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e
Wheels
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WheelsWheels
ehicle supporehicle suppor
ehicle suppor
ehicle supporehicle suppor
tedted
ted
tedted
Refer to the Owner’s Manual to identify the correct location of the jack for raising the vehicle.
Jack up the vehicle, and secure it on a pair of
jack stands, again referring to the Owner’s
Manual for jack location joints.
After securing the vehicle at a convenient height,
remove the front wheels.
NN
ote: Tote: T
N
ote: T
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.
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 8
SS
tep 2tep 2
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tep 2
SS
tep 2tep 2
DD
isconnect Sisconnect S
D
isconnect S
DD
isconnect Sisconnect S
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immediatelyimmediately
immediately
immediatelyimmediately
it is loose or removed, it is likely that more fluid will drip during brake installation.it is loose or removed, it is likely that more fluid will drip during brake installation.
it is loose or removed, it is likely that more fluid will drip during brake installation.
it is loose or removed, it is likely that more fluid will drip during brake installation.it is loose or removed, it is likely that more fluid will drip during brake installation.
tock Btock B
tock B
tock Btock B
pilled brpilled br
pilled br
pilled brpilled br
. T. T
ake carake car
. T
ake car
. T. T
ake carake car
rake Linerake Line
rake Line
rake Linerake Line
ake fluid will damage most painted surake fluid will damage most painted sur
ake fluid will damage most painted sur
ake fluid will damage most painted surake fluid will damage most painted sur
e to ensure to ensur
e to ensur
e to ensure to ensur
e that the cap is secure that the cap is secur
e that the cap is secur
e that the cap is secure that the cap is secur
The ABS lead is attached, using clips or cable
ties, to the stock brake line in three places, and
it must be detached before the brake line can be
removed.
Note: The brake line shown here is not theNote: The brake line shown here is not the
Note: The brake line shown here is not the
Note: The brake line shown here is not theNote: The brake line shown here is not the
stock line, but it gives an accurate represen-stock line, but it gives an accurate represen-
stock line, but it gives an accurate represen-
stock line, but it gives an accurate represen-stock line, but it gives an accurate representation of the stock line configuration.tation of the stock line configuration.
tation of the stock line configuration.
tation of the stock line configuration.tation of the stock line configuration.
ely installed on the master cylinderely installed on the master cylinder
ely installed on the master cylinder
ely installed on the master cylinderely installed on the master cylinder
faces, and shouldfaces, and should
faces, and should
faces, and shouldfaces, and should
be cleaned off be cleaned off
be cleaned off
be cleaned off be cleaned off
. If. If
. If
. If. If
Snip the cable ties, using diagonal cutters, and
place the ABS line out of the way.
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.
Loosen the hard line fitting, using a 13mm flare
wrench, while using a 17mm wrench to hold the
brake line fitting.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 9
SS
tep 2tep 2
S
tep 2
SS
tep 2tep 2
DD
isconnect Sisconnect S
D
isconnect S
DD
isconnect Sisconnect S
Remove the chassis bracket, using a 10mm
wrench or socket, and retain the bolt.
tock Btock B
tock B
tock Btock B
rake Linerake Line
rake Line
rake Linerake Line
Remove the brake line retaining clip, using a
pair of needle-nose pliers or a screwdriver.
Remove the hard line fitting, and place one of
the rubber caps over the end of the hard line, to
control fluid loss during the installation.
Note: The stock chassis bracket will remainNote: The stock chassis bracket will remain
Note: The stock chassis bracket will remain
Note: The stock chassis bracket will remainNote: The stock chassis bracket will remain
attached to the brake line, and does not needattached to the brake line, and does not need
attached to the brake line, and does not need
attached to the brake line, and does not needattached to the brake line, and does not need
to be retained.to be retained.
to be retained.
to be retained.to be retained.
Install the supplied replacement bracket in the
same location as the stock bracket, using a 10mm
wrench or socket to secure the stock bolt.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 10
SS
tep 3tep 3
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tep 3
SS
tep 3tep 3
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Remove the two stock caliper bolts, using a 15mm
wrench or socket.
NN
ote: Fote: F
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ote: F
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ote: Fote: F
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
vv
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actoractor
actor
actoractor
tock Ctock C
tock C
tock Ctock C
aliper & Raliper & R
aliper & R
aliper & Raliper & R
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
otorotor
otor
otorotor
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.
If there are rotor-retaining washers in place, pry
them away from the rotor, using a screwdriver,
then remove them, using needle-nose pliers.
Note: The rotor-retaining washers will notNote: The rotor-retaining washers will not
Note: The rotor-retaining washers will not
Note: The rotor-retaining washers will notNote: The rotor-retaining washers will not
be reused, so you may find it easiest to sim-be reused, so you may find it easiest to sim-
be reused, so you may find it easiest to sim-
be reused, so you may find it easiest to sim-be reused, so you may find it easiest to simply twist and tear them off.ply twist and tear them off.
ply twist and tear them off.
ply twist and tear them off.ply twist and tear them off.
Then remov e 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 nut onbeing pulled off. If so, place a wheel nut on
being pulled off. If so, place a wheel nut on
being pulled off. If so, place a wheel nut onbeing pulled off. If so, place a wheel nut on
one of the studs first, to prevent the rotorone of the studs first, to prevent the rotor
one of the studs first, to prevent the rotor
one of the studs first, to prevent the rotorone of the studs 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.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 11
SS
tep 4tep 4
S
tep 4
SS
tep 4tep 4
RR
emoemo
vv
e De D
R
emo
RR
emoemo
The dust shield must be permanently removed
from each front wheel, to accommodate the
AeroRotors.
Remove the rivets which hold the dust shield in
place, by either drilling out their centers, or by
chiseling them off. Then slide the dust shield
off of the hub.
v
e D
vv
e De D
ust Sust S
ust S
ust Sust S
hield, and Ihield, and I
hield, and I
hield, and Ihield, and I
nstall Cnstall C
nstall C
nstall Cnstall C
aliper Baliper B
aliper B
aliper Baliper B
racketracket
racket
racketracket
Remove the Jet nuts and washers from the caliper mounting bracket, and put them in a safe
place for later use.
Install the caliper bracket, using the supplied
caliper mounting bolts, and torque them to
lb-ftlb-ft
lb-ft, using a 17mm socket.
lb-ftlb-ft
5555
55
5555
Apply a few drops of the supplied Loctite 262 to
the end of the threads of the supplied caliper
mounting bolts.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 12
Step 5Step 5
Step 5
Step 5Step 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 , taking car e to
ensure that the rotor is seated squarely on the
hub face. If necessary , clean the face of the hub,
using a wire brush or similar means.
If necessary, place a wheel nut on one of the
studs, to prevent the rotor from falling off of the
hub.
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 theinside the rotor should lean to the rear of the car on the top side of the rotor (see the
inside the rotor should lean to the rear of the car on the top side of the rotor (see the
inside the rotor should lean to the rear of the car on the top side of the rotor (see theinside the rotor should lean to the rear of the car on the top side of the rotor (see the
following pages for more-detailed images).following pages for more-detailed images).
following pages for more-detailed images).
following pages for more-detailed images).following pages for more-detailed images).
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 13
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
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, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 14
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 15
CC
aliper Component Ialiper Component I
C
aliper Component I
CC
aliper Component Ialiper Component I
dentificationdentification
dentification
dentificationdentification
Bolt-in Bridge
Cross Over Tube
Pad Retaining Clip
Bridge Bolts Bleed Screw
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 16
Step 6Step 6
Step 6
Step 6Step 6
II
nstall Cnstall C
I
nstall C
II
nstall Cnstall C
NN
ote: The images in this section may not be of the vehicle noted, but they give a properote: The images in this section may not be of the vehicle noted, but they give a proper
ote: The images in this section may not be of the vehicle noted, but they give a proper
N
ote: The images in this section may not be of the vehicle noted, but they give a properote: The images in this section may not be of the vehicle noted, but they give a proper
NN
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 . If installing a four-wheel kit, with ST40 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
Remove the two bolts holding the caliper bridge
in place, using a 5mm Allen wrench.
Bridge Bolts
In order to stiffen the caliper, the bridge must
have a snug fit, 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.
Remove 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.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 17
SS
tep 6 (Conttep 6 (Cont
S
tep 6 (Cont
SS
tep 6 (Conttep 6 (Cont
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 ensure that the caliper is squar e and
evenly started on both studs. It may be necessary to use a mallet to gently tap the caliper into
position.
’’
d.)d.)
’
d.)
’’
d.)d.)
aliper and Paliper and P
aliper and P
aliper and Paliper and P
adsads
ads
adsads
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
fore!)fore!)
fore!)
fore!)fore!)
y havy hav
e been installed backware been installed backwar
y hav
e been installed backwar
y havy hav
e been installed backware been installed backwar
d be-d be-
d be-
d be-d be-
Install the Jet nuts onto each stud, with one
12mm washer under each nut. Tighten the Jet
nuts to
40 lb-ft 40 lb-ft
40 lb -ft of torque, using a 1/2” socket.
40 lb-ft 40 lb-ft
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 18
SS
tep 6 (Conttep 6 (Cont
S
tep 6 (Cont
SS
tep 6 (Conttep 6 (Cont
II
nstall Cnstall C
I
nstall C
II
nstall Cnstall C
Apply a light film of anti-seize compound onto
the bridge bolt shafts and threads.
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.
Note: The bridge is directional, and shouldNote: The bridge is directional, and should
Note: The bridge is directional, and should
Note: The bridge is directional, and shouldNote: The bridge is directional, and should
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.
’’
d.)d.)
’
d.)
’’
d.)d.)
aliper and Paliper and P
aliper and P
aliper and Paliper and P
adsads
ads
adsads
Insert the first bridge bolt, from the outside of
the caliper, and start the first few threads, using
a 5mm Allen wrench.
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
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.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 19
Step 7Step 7
Step 7
Step 7Step 7
AA
ttach Sttach S
A
ttach S
AA
ttach Sttach S
tainless Stainless S
tainless S
tainless Stainless S
teel Bteel B
teel B
teel Bteel B
rake Linerake Line
rake Line
rake Linerake Line
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 caliper.
Copper
crush washers
Banjo bolt
apprappr
oo
Torque the banjo bolt to
ftft
ft, using a 14mm wrench or socket. Do not use
ftft
a torque wrench, as overtightening the bolt can
strip the aluminum threads, causing irreparable
damage to the caliper.
Note: The orientation of the banjo fittingNote: The orientation of the banjo fitting
Note: The orientation of the banjo fitting
Note: The orientation of the banjo fittingNote: The orientation of the banjo fitting
should be as shown in the photograph to theshould be as shown in the photograph to the
should be as shown in the photograph to the
should be as shown in the photograph to theshould be as shown in the photograph to the
left, with the brake line pointing upward andleft, with the brake line pointing upward and
left, with the brake line pointing upward and
left, with the brake line pointing upward andleft, with the brake line pointing upward and
angled approximately 45angled approximately 45
angled approximately 45°
angled approximately 45angled approximately 45
the vehicle.the vehicle.
the vehicle.
the vehicle.the vehicle.
appr
apprappr
ximately 14 lb-ximately 14 lb-
o
ximately 14 lb-
oo
ximately 14 lb-ximately 14 lb-
toward the rear of toward the rear of
toward the rear of
toward the rear of toward the rear of
Remove the rubber cap from the chassis hard
line. Then insert the stainless steel brake line
fitting through the chassis bracket, and screw it
onto the hard line fitting by hand for a few turns,
to ensure that it is properly engaged.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 20
SS
tep 7 (Conttep 7 (Cont
S
tep 7 (Cont
SS
tep 7 (Conttep 7 (Cont
AA
ttach Sttach S
A
ttach S
AA
ttach Sttach S
Reinstall the brake line retaining clip, using a
mallet to gently tap it into place.
’’
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
Use a 17mm line wrench to hold the stainless
line inboard fitting, while using a 13mm flare
wrench to tighten the hard line fitting.
After securing the brake line, turn the wheels
lock-to-lock, to ensure that the brake line is not
binding in any way, nor interfering with any
suspension component, including the CV boot
and axle/drive shaft.
Once the stainless steel brake line is properly
positioned, reattach the ABS line to the brake
line by applying three cable ties, with rubber
tubing segments as standoffs, to hold it in place.
First loop each cable tie around the line locator
on the ABS lead, then slip both ends of the tie
through the rubber tubing segment, and around
the stainless brake line.
Secure each cable tie loosely, until all three are
in place, and double-check that the brake/ABS
lines are not binding nor interfering with any
suspension component. Then pull each cable
tie tight, to lock them securely in place.
Adjust the line, if necessary, by loosening the
banjo bolt on the caliper, and realigning the
brake line, or by loosening the inboard end of
the line, and slightly re-clocking the fitting.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 21
Step 8Step 8
Step 8
Step 8Step 8
Bleed BrakesBleed Brakes
Bleed Brakes
Bleed BrakesBleed Brakes
Complete the installation on both sides of the vehicle before bleeding the system.
WW
arar
ning: Dning: D
W
ar
ning: D
WW
arar
ning: Dning: D
in any way, nor interfering with any suspension component, including the CV boot and the axle/in any way, nor interfering with any suspension component, including the CV boot and the axle/
in any way, nor interfering with any suspension component, including the CV boot and the axle/
in any way, nor interfering with any suspension component, including the CV boot and the axle/in any way, nor interfering with any suspension component, including the CV boot and the axle/
drivdriv
e shaft. Adjust each line, if necessare shaft. Adjust each line, if necessar
driv
e shaft. Adjust each line, if necessar
drivdriv
e shaft. Adjust each line, if necessare shaft. Adjust each line, if necessar
line, or by loosening the inboard end of the line, and slightly re-clocking the fitting.line, or by loosening the inboard end of the line, and slightly re-clocking the fitting.
line, or by loosening the inboard end of the line, and slightly re-clocking the fitting.
line, or by loosening the inboard end of the line, and slightly re-clocking the fitting.line, or by loosening the inboard end of the line, and slightly re-clocking the fitting.
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
eser
esereser
v
vv
oiroir
oir
oiroir
r
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:
ouble-check that the stainless steel brouble-check that the stainless steel br
ouble-check that the stainless steel br
ouble-check that the stainless steel brouble-check that the stainless steel br
yy
y
yy
. K. K
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
un drun dr
un dr
un drun dr
yy
, and to dr, and to dr
y
, and to dr
yy
, and to dr, and to dr
ake lines yake lines y
ake lines y
ake lines yake lines y
, by loosening the banjo bolt, and r, by loosening the banjo bolt, and r
, by loosening the banjo bolt, and r
, by loosening the banjo bolt, and r, by loosening the banjo bolt, and r
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
aw in airaw in air
aw in air
aw in airaw in air
ouou
’’
vv
e just installed are just installed ar
ou
’
v
e just installed ar
ouou
’’
vv
e just installed are just installed ar
aining the master cylinderaining the master cylinder
aining the master cylinder
aining the master cylinderaining the master cylinder
. D. D
oing so may roing so may r
. D
oing so may r
. D. D
oing so may roing so may r
ealigning the brealigning the br
ealigning the br
ealigning the brealigning the br
e not bindinge not binding
e not binding
e not bindinge not binding
o not alloo not allo
o not allo
o not alloo not allo
esult in the bresult in the br
esult in the br
esult in the bresult in the br
akeake
ake
akeake
ww
w
ww
akeake
ake
akeake
Though a torque wrench is not typically used on bleed screws, as a reference, the torque for bleed
screws should be
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.
om any painted surom any painted sur
om any painted sur
om any painted surom any painted sur
approximately 100-140 lb-INCHapproximately 100-140 lb-INCH
approximately 100-140 lb-INCH.
approximately 100-140 lb-INCHapproximately 100-140 lb-INCH
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
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 22
Step 9Step 9
Step 9
Step 9Step 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. It 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 following 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
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eight
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3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 23
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 TO YOUR NEW RO TORS.
WW
W
WW
StopTech coats non-plated AeroRotors 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
ORKING AORKING A
TER beforTER befor
TER befor
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.
OO
W W
THESE PRTHESE PR
O
W
THESE PR
OO
W W
THESE PRTHESE PR
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
WW
W
WW
OO
TT
ORS, AND ORS, AND
O
T
ORS, AND
OO
TT
ORS, AND
ORS, AND
AA
CITCIT
CIT
CITCIT
YY
Y
YY
A
AA
OCEDURESOCEDURES
OCEDURES
OCEDURESOCEDURES
WILLWILL
WILL
WILLWILL
..
.
..
APAP
AP
APAP
Bed-in yBed-in y
Bed-in y
Bed-in yBed-in y
serser
ving the prving the pr
ser
ving the pr
serser
ving the prving the pr
follofollo
follo
follofollo
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
NN
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 driver will experience approximately 1 to 1.1G’s of deceleration.
At 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
irir
V
ir
VV
irir
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
y instance of a “
erer
y instance of a “y instance of a “
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, Torrance, CA 90505 (310) 325-4799
www.stoptech.com 24
RR
otor and Potor and P
R
otor and P
RR
otor and Potor and P
NN
ote: Bote: B
N
ote: B
NN
ote: Bote: B
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 OT OR, CAUSING 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.
ad Bed-in (Contad Bed-in (Cont
ad Bed-in (Cont
ad Bed-in (Contad Bed-in (Cont
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
’’
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
topTtopT
S
topT
SS
topTtopT
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
YY
OUR FOOOUR FOO
Y
OUR FOO
YY
OUR FOOOUR FOO
RR
OO
TT
R
O
T
RR
OO
TT
eally stareally star
eally star
eally stareally star
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 “
t to “
t to “t to “
TT
O A CO A C
T
O A C
TT
O A CO A C
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
VIBRA
VIBRAVIBRA
TION.TION.
TION.
TION.TION.
wn abown abo
wn abo
wn abown abo
EDAL. PEDAL. P
EDAL. P
EDAL. PEDAL. P
vv
v
vv
d bed-in cyd bed-in cy
d bed-in cy
d bed-in cyd bed-in cy
cycy
cy
cycy
OP OP
WHEN WHEN
OP
WHEN
OP OP
WHEN WHEN
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
cle is typically necessarcle is typically necessar
clecle
” is a series of stops, follo” is a series of stops, follo
cle
” is a series of stops, follo
clecle
” is a series of stops, follo” is a series of stops, follo
oads. If going abooads. If going abo
oads. If going abo
oads. If going abooads. If going abo
THE SYSTEM IS HOTHE SYSTEM IS HO
THE SYSTEM IS HO
THE SYSTEM IS HOTHE SYSTEM IS HO
AD MAAD MA
AD MA
AD MAAD MA
TERIAL MATERIAL MA
TERIAL MA
TERIAL MATERIAL MA
Y Y
TRANSFER ONTTRANSFER ONT
Y
TRANSFER ONT
Y Y
TRANSFER ONTTRANSFER ONT
vv
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y befory befor
y befor
y befory befor
ww
ed bed b
w
ed b
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ed bed b
e the legal speede the legal speed
e the legal speed
e the legal speede the legal speed
WHILE LEAWHILE LEA
WHILE LEA
WHILE LEAWHILE LEA
e thee the
e the
e thee the
y a cool-y a cool-
y a cool-
y a cool-y a cool-
VINGVING
VING
VINGVING
O O
THETHE
O
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O O
THETHE
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 25
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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topTtopT
ech.ech.
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ech.ech.
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