StopTech ST-40 User Manual 2

Installation Instructions

2000+ Lincoln LS

355mm Front

Big Brake Upgrade

ST-40 Caliper

98-530-1470

Rev. A 03-18-05

COMPONENT IDENTIFICATION

AeroRotor and Hat Assemblies

Caliper Brackets	High-Performance
	Street Pads

Calipers

Stainless Steel Braided Lines and Hardware

Lincoln LS Front Big Brake Kit

(This is a representative photograph. The actual components in your kit may appear slightly different.)

3541 Unit A, Lomita Boulevard, Torrance, CA 90505	[phone]
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APPLICATION DISCLAIMER

Caliper Clearance

Most 17” wheels will clear the outer diameter of the caliper for a 328mm or 332mm rotor kit. For 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 www.stoptech.com, and click on the ‘Wheel Fitment Charts’ 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 you have a full understanding of how to accurately measure 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 [phone] - extension 105, or send an e-mail to [e-mail].

Note: Final fitment of the wheel to the caliper is the responsibility of the customer.

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

Caliper, Hat and Bracket Finish Disclaimer

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.

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

APPLICATION DISCLAIMER (Cont’d.)

Permanent Removal of Dust Shield

The dust shield must be permanently removed from both front wheels of the vehicle, 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. For anyone who is not competent or comfortable performing these operations, StopTech firmly recommends seeking the services of a trained professional.

Brake Noise

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.

Brake Vibration - THIS IS IMPORTANT!

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 extreme 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, uneven pad deposits will occur, causing an ever-worsening vibration. Failure to immediately address a pad deposition/vibration issue may lead to permanent damage of the rotors. Please read and understand the bed-in procedure included in this manual. If you have any questions, please contact the StopTech Customer Service Department on [phone] - extension 105, or you can e-mail directly to [e-mail].

Note: StopTech is not liable for vibrations caused by extreme usage or improper bed-in of pads and rotors.

All trademarks are properties of their respective owners. StopTech LLC is neither associated nor affiliated with, nor sponsored by Ford.

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

Important Notices

Wheel Fitment

Do not assume that your wheels will fit. An outline drawing of your StopTech Big Brake kit is available on our website at www.stoptech.com. Measure the 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 INSTALL YOUR KIT!

Cleaning 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.

Rotor and Pad Bed-in

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 bedin 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 www.stoptech.com for further information.

Safety Notice

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, expressed or implied, for the improper installation or use of this product or its components.

Liability No Warranty

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 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-perfor- mance after installation. Under no circumstances is StopTech liable for labor charges or loss of use.

Contact StopTech

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 [phone] - extension 105, or you can e- mail directly to [e-mail].

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

Lincoln LS Front Axle Kit

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

Kit 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

3541 Unit A, Lomita Boulevard, Torrance, CA 90505	[phone]
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Lincoln LS Front Axle Kit (Cont’d)

Tools and Equipment Required

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 Torque 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.

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

Step 1

Raise Vehicle, and Remove Wheels

Note: All photographs show a left-hand side installation, unless otherwise noted. Some of the images in this manual may not be of the vehicle noted, but they give a proper representation of the correct installation.

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

Warning: Never leave any vehicle supported 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.

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.

Note: To ensure safety, the parking brake must be applied before removing the front 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 you’re 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.

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