Stoptech St-40 caliper User manual

Installation Instructions

Corvette C5

1997 - 2004

355mm Front

Big Brake Upgrade

ST-40 Caliper

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

CC

COMPONENT IDENTIFICAOMPONENT IDENTIFICA

OMPONENT IDENTIFICAOMPONENT IDENTIFICA

OMPONENT IDENTIFICATIONTION

TIONTION

TION

3541 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 2

Stainless Braided Brake Line and Hardware

High-Performance Street Pads

Caliper Bracket

ST-40 Caliper

355mm AeroRotor and Hat Assembly

BB

Big Big B

ig Big B

ig Brake Krake K

rake Krake K

rake Kit for the Corit for the Cor

it for the Corit for the Cor

it for the Corvv

vv

vette C5ette C5

ette C5ette C5

ette C5

(Thisisarepresentativephotograph. Theactualcomponentsin

your kit may appear slightly different.)

APPLICAAPPLICA

APPLICATION DISCLTION DISCL

TION DISCLTION DISCL

TION DISCLAIMERAIMER

AIMERAIMER

AIMER

Caliper ClearanceCaliper Clearance

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 wwwwww

wwwwww

www.stoptech.com.stoptech.com

.stoptech.com.stoptech.com

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

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 di-

mension 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 ques-

tions or difficulties, please contact the StopTech Customer Service Department on (310) 325-4799 -

extension 105, or send an e-mail to [email protected][email protected]

[email protected][email protected]

[email protected].

NN

Note: Fote: F

ote: Fote: F

ote: Final 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 rinal fitment of the wheel to the caliper is the r

inal fitment of the wheel to the caliper is the responsibility of the customeresponsibility of the customer

esponsibility of the customeresponsibility of the customer

esponsibility of the customer..

..

.

Wheel SpacersWheel Spacers

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 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

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

specified and installed.specified and installed.

specified and installed.

CC

Caliperaliper

aliperaliper

aliper, H, H

, H, H

, Hat and Bat and B

at and Bat and B

at and Bracket Fracket F

racket Fracket F

racket Finish Dinish D

inish Dinish D

inish Disclaimerisclaimer

isclaimerisclaimer

isclaimer

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 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 3

APPLICAAPPLICA

APPLICATION DISCLTION DISCL

TION DISCLTION DISCL

TION DISCLAIMER (ContAIMER (Cont

AIMER (ContAIMER (Cont

AIMER (Cont’’

’’

’d.)d.)

d.)d.)

d.)

All trademarAll trademar

All trademarks arks ar

ks arks ar

ks are pre pr

e pre pr

e properoper

operoper

operties of their rties of their r

ties of their rties of their r

ties of their respectivespectiv

espectivespectiv

espective oe o

e oe o

e owners. Swners. S

wners. Swners. S

wners. StopTtopT

topTtopT

topTech LLech LL

ech LLech LL

ech LLC is neither associ-C is neither associ-

C is neither associ-C is neither associ-

C is neither associ-

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.

BB

Brakerake

rakerake

rake Vibration -Vibration -

Vibration -Vibration -

Vibration - THIS IS IMPORTHIS IS IMPOR

THIS IS IMPORTHIS IS IMPOR

THIS IS IMPORTT

TT

TANT!ANT!

ANT!ANT!

ANT!

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 preci-

sion manufacturing and inspection typically mean that run-out is not an issue. Modern produc-

tion methods ensure that the rotor run-out is within +/- 0.002” when installed on a StopTech alumi-

num 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 proce-

dure 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

[email protected][email protected]

[email protected].

NN

Note: Sote: S

ote: Sote: S

ote: StopTtopT

topTtopT

topTech is not liable for vibrech is not liable for vibr

ech is not liable for vibrech is not liable for vibr

ech is not liable for vibrations caused by eations caused by e

ations caused by eations caused by e

ations caused by extrxtr

xtrxtr

xtreme usage or impreme usage or impr

eme usage or impreme usage or impr

eme usage or improper bed-in ofoper bed-in of

oper bed-in ofoper bed-in of

oper bed-in of

pads and rotors.pads and rotors.

pads and rotors.

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.

BB

Brake Nrake N

rake Nrake N

rake Noiseoise

oiseoise

oise

Certain brake pad compounds make more noise than others. Proper anti-squeal shim plates be-

tween 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.

3541 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 4

PP

Perer

erer

ermanent Mmanent M

manent Mmanent M

manent Modification to Loodification to Lo

odification to Loodification to Lo

odification to Loww

ww

wer Ber B

er Ber B

er Ball Jall J

all Jall J

all Jointsoints

ointsoints

oints

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.

II

Impormpor

mpormpor

mportant Ntant N

tant Ntant N

tant Noticesotices

oticesotices

otices

Cleaning of RotorsCleaning of Rotors

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 installa-

tion. Brake cleaner is not as effective as soap and water. Even if it doesn’t look as if anything is

coming off the rotor, the rust inhibitor is there, and must be entirely cleaned. Rotors will quickly

rust without protection, so if the rotor is not rusty, it’s still coated. After cleaning, you may see the

rotor start to develop a slight rust color. This is normal, and indicates that all of the rust inhibitor

has been removed.

RR

Rotor and Potor and P

otor and Potor and P

otor and Pad Bed-inad Bed-in

ad Bed-inad Bed-in

ad 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

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 wwwwww

wwwwww

www.stoptech.com.stoptech.com

.stoptech.com.stoptech.com

.stoptech.com for further

information.

Wheel FitmentWheel Fitment

Wheel 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 wwwwww

wwwwww

www.stoptech.com.stoptech.com

.stoptech.com.stoptech.com

.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!

Contact SContact S

Contact StopTtopT

topTtopT

topTechech

echech

ech

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

e-mail directly to [email protected][email protected]

[email protected][email protected]

[email protected].

SS

Safety Nafety N

afety Nafety N

afety Noticeotice

oticeotice

otice

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 installa-

tion or use of this product or its components.

Liability NLiability N

Liability Noo

oo

o WW

WW

Warrantyarranty

arrantyarranty

arranty

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-

performance after installation. Under no circumstances is StopTech liable for labor charges or loss

of use.

3541 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 5

CorCor

Corvv

vv

vette C5 Fette C5 F

ette C5 Fette C5 F

ette C5 Frr

rr

ront Axle Kont Axle K

ont Axle Kont Axle K

ont Axle Kitit

itit

it

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

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

Your StopTech Big Brake kit includes the following:

1 pair of ST-40 four-piston calipers, sized specifically for your vehicle

1 set of high-performance street pads (not suitable for track use)

1 pair of 355 x 32mm two-piece rotor assemblies

1 pair of aluminum caliper adapter brackets

2 pair of 7/16-20 self-locking Jet nuts

2 pair of 12mm washers

1 pair of stainless steel brake lines

1 pair of banjo bolts

2 pair of copper crush washers

1 pair of rubber end caps

1 caplet of Loctite 262

TT

Tools and Eools and E

ools and Eools and E

ools and Equipment Rquipment R

quipment Rquipment R

quipment Requirequir

equirequir

equireded

eded

ed

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

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-

sionallysionally

sionally, ho, ho

, ho, ho

, howw

ww

wevev

evev

everer

erer

er, manufactur, manufactur

, manufactur, manufactur

, manufacturers use alterers use alter

ers use alterers use alter

ers use alternate fasteners, so itnate fasteners, so it

nate fasteners, so itnate fasteners, so it

nate fasteners, so it’’

’’

’s advisable to check that eachs advisable to check that each

s advisable to check that eachs advisable to check that each

s advisable to check that each

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.

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 rec-

ommends 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 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 6

3541 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 7

Step 1Step 1

Step 1

RR

Raiseaise

aiseaise

aise VV

VV

Vehicle, and Rehicle, and R

ehicle, and Rehicle, and R

ehicle, and Remoemo

emoemo

emovv

vv

vee

ee

e WheelsWheels

WheelsWheels

Wheels

WW

Warar

arar

arning: Nning: N

ning: Nning: N

ning: Nevev

evev

ever leaver leav

er leaver leav

er leave any ve any v

e any ve any v

e any vehicle supporehicle suppor

ehicle supporehicle suppor

ehicle supportedted

tedted

ted

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

with only a jack. Always use jack-stands.

Alevel, stable and clean surface, suitable for sup-

porting the vehicle on jack-stands, should be

used for the installation.

For a front kit installation, apply the parking

brake, then break loose the lug nuts on both

front wheels before jacking up the vehicle.

NN

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

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

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.

Aftersecuringthevehicle at a convenient height,

remove the front wheels.

NN

Note: Tote: T

ote: Tote: T

ote: To ensuro ensur

o ensuro ensur

o ensure safetye safety

e safetye safety

e safety, the par, the par

, the par, the par

, the parking brking br

king brking br

king brakeake

akeake

ake

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

must be applied before removing the front

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 you’re working on,

and if you’re installing a trailing caliper, turn

thesteering away from the side thatyou’re work-

ingon. Thiswill make access to the caliper bolts

easier.

If necessary, place a wheel nut on one of the

studs, to prevent the rotor from falling.

Step 2Step 2

Step 2

Disconnect Stock Brake LineDisconnect Stock Brake Line

Disconnect Stock Brake Line

3541 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 8

WW

Warar

arar

arning: Bning: B

ning: Bning: B

ning: Brr

rr

rake fluid will damage most painted surake fluid will damage most painted sur

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

ake fluid will damage most painted surfaces. Ifaces. I

faces. Ifaces. I

faces. Immediately clean spilled brmmediately clean spilled br

mmediately clean spilled brmmediately clean spilled br

mmediately clean spilled brakeake

akeake

ake

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

cylindercylinder

cylinder. 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 remoemo

emoemo

emovv

vv

ved, it is likely that mored, it is likely that mor

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

ed, it is likely that more fluid will drip during bre fluid will drip during br

e fluid will drip during bre fluid will drip during br

e fluid will drip during brakeake

akeake

ake

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 ap-

propriate cleaning agent.

Use a 13mm flare wrench to slightly loosen the

hard line fitting.

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 re-

move the bracket holding the inboard end of

the stock brake line to the chassis bracket. Take

care to retain the clip for later use.

Step 3Step 3

Step 3

RR

Remoemo

emoemo

emovv

vv

ve Se S

e Se S

e Stock Ctock C

tock Ctock C

tock Caliper & Raliper & R

aliper & Raliper & R

aliper & Rotorotor

otorotor

otor

3541 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 9

Remove the caliper with the stock brake line at-

tached. There may be some leakage from the

openendofthe brake line, especially if the pads/

pistons on the caliper are retracted.

NN

Note: Fote: F

ote: Fote: F

ote: Factoractor

actoractor

actory-installed caliper bolts may bey-installed caliper bolts may be

y-installed caliper bolts may bey-installed caliper bolts may be

y-installed caliper bolts may be

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-

chase 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

good position to turn the wrench or socket.good position to turn the wrench or socket.

good position to turn the wrench or socket.

Remove the stock rotor, by pulling it off of the

hub by hand.

Removethetwo stockcaliperbolts,usinga21mm

wrench or socket, and retain the bolts for later

use.

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

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

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

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

from falling when it comes loose.from falling when it comes loose.

from falling when it comes loose.

SS

Step 4tep 4

tep 4tep 4

tep 4

Install Caliper BracketInstall Caliper Bracket

Install Caliper Bracket

3541 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 10

Install the caliper bracket, using the stock cali-

per mounting bolts, with the bracket mounted

on the outboard side of the mounting lugs, and

the bolts inserted from the inboard side.

Remove the Jetnuts andwashersfrom the caliper

mounting bracket, and put them aside for later

use.

Tighten the caliper bracket bolts, using a 21mm

wrench or socket, then torque the bolts to 125125

125125

125

lb-ftlb-ft

lb-ft.

Place a few drops of the supplied Loctite 262 on

the threads of each stock caliper bolt.

SS

Step 5tep 5

tep 5tep 5

tep 5

Install AeroRotor AssemblyInstall AeroRotor Assembly

Install AeroRotor Assembly

AeroRotors MUSTMUST

MUSTMUST

MUST be cleaned with soap and water prior to installation. Not doing so will damage

the rotors and pads, and will prevent the brakes from performing properly.

WW

Warar

arar

arning: Dning: D

ning: Dning: D

ning: Do not skip this step!o not skip this step!

o not skip this step!o not skip this step!

o not skip this step!

Even 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

performanceof yournew brakesystem.

3541 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 11

NN

Note: Tote: T

ote: Tote: T

ote: Take carake car

ake carake car

ake care to ensure to ensur

e to ensure to ensur

e to ensure that the re that the r

e that the re that the r

e that the rotor assembly is on the corrotor assembly is on the corr

otor assembly is on the corrotor assembly is on the corr

otor assembly is on the correct side of the carect side of the car

ect side of the carect side of the car

ect side of the car, as r, as r

, as r, as r

, as revev

evev

eversingersing

ersingersing

ersing

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

marmar

marked “Lked “L

ked “Lked “L

ked “L” and “R” and “R

” and “R” and “R

” and “R” with or” with or

” with or” with or

” with orange tags on the range tags on the r

ange tags on the range tags on the r

ange tags on the rotor hats. If the tags arotor hats. If the tags ar

otor hats. If the tags arotor hats. If the tags ar

otor hats. If the tags are not legible, the ve not legible, the v

e not legible, the ve not legible, the v

e not legible, the vanesanes

anesanes

anes

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

and 14 for more-detailed images).and 14 for more-detailed images).

and 14 for more-detailed images).

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 wire

brush or similar means.

Place a couple of wheel nuts on the studs, to pre-

vent the rotor from falling during brake installa-

tion.

SS

Step 5tep 5

tep 5tep 5

tep 5 (Cont(Cont

(Cont(Cont

(Cont’’

’’

’d.)d.)

d.)d.)

d.)

Install AeroRotor AssemblyInstall AeroRotor Assembly

Install AeroRotor Assembly

3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 12

It may be necessary to clearance the lower ball

joint slightly, to clear the inboard face of the

AeroRotorduringfullsuspension travel. Acoarse

file can remove the material, although a power

grinder is more efficient, if used properly.

Remove ridge in this area

Ridge Width

Install the rotor, and check the proximity of the

lower ball joint to the inner rotor face. Turn the

wheellock-to-lock,todeterminehowfararound

the front and back edge needs to be clearanced.

Remove thelipwhich protrudesaroundthe outer

edge of the ball joint (the approximate area is

shown in the photograph to the left).

NN

Note: If only the lip arote: If only the lip ar

ote: If only the lip arote: If only the lip ar

ote: If only the lip around the outer ridge isound the outer ridge is

ound the outer ridge isound the outer ridge is

ound the outer ridge is

removed, the structural integrity of the lowerremoved, the structural integrity of the lower

removed, 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

not comfortable making this modification, seeknot comfortable making this modification, seek

not comfortable making this modification, seek

the help of a qualified professional.the help of a qualified professional.

the help of a qualified professional.

With the suspension at FULL DROOP, there

shouldbeaclearanceof3.5-4.8mm (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

Left-Side Rotor

Right-Side Rotor

DD

Drivriv

rivriv

riverer

erer

er’’

’’

’s Lefts Left

s Lefts Left

s Left

DD

Drivriv

rivriv

riverer

erer

er’’

’’

’s Rights Right

s Rights Right

s Right

3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 13

Outboard SideOutboard Side

Outboard Side

Outboard SideOutboard Side

Outboard Side

3541 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 14

CC

Caliper Component Ialiper Component I

aliper Component Ialiper Component I

aliper Component Identificationdentification

dentificationdentification

dentification

The ST-40 original equipment caliper uses a common Porsche-style pad.

The Friction Materials Standards Institute (FMSI) number for the pad backing plate is D372.

For further pad interchange information, please see the FAQ section of the StopTech website at:

www.stoptech.com

3541 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 15

Use a light film of anti-seize on the bridge

bolt shafts and threads

Remove the two bolts holding the caliper bridge

in place, using a 5mm Allen wrench.

Remove the caliper bridge, taking note of the di-

rection in which it is installed, and the correct

location of the pad-retaining wire clip, which

typically, but not always, remainsattached to the

bridge.

Bridge Bolts

Determine the left- and right-hand side calipers. They are clearly marked on the box, but as a check,

thebleedscrewsarealwayspositionedatthe top of the caliper. Ifinstalling a four-wheel kit, with ST-

40 calipers on the front and rear of the vehicle, be sure that the correct caliper is on each corner. The

calipers with the smaller piston sizes go on the rear of the vehicle.

SS

Step 6tep 6

tep 6tep 6

tep 6

II

Install Cnstall C

nstall Cnstall C

nstall Caliper and Paliper and P

aliper and Paliper and P

aliper and Padsads

adsads

ads

3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 16

NN

Note: The images in this section may not be of the vote: The images in this section may not be of the v

ote: The images in this section may not be of the vote: The images in this section may not be of the v

ote: The images in this section may not be of the vehicle noted, but theehicle noted, but the

ehicle noted, but theehicle noted, but the

ehicle noted, but they givy giv

y givy giv

y give a pre a pr

e a pre a pr

e a properoper

operoper

oper

representation of the correct installation.representation of the correct installation.

representation of the correct installation.

In order to stiffen the caliper, the bridge must fit

snugly, and the bolts may be tight when remov-

ing 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 in-

sert.

NN

Note: When the pad-rote: When the pad-r

ote: When the pad-rote: When the pad-r

ote: When the pad-retaining clip is orientedetaining clip is oriented

etaining clip is orientedetaining clip is oriented

etaining clip is oriented

correctly, its welded joint should not be vis-correctly, its welded joint should not be vis-

correctly, its welded joint should not be vis-

ible thrible thr

ible through the bridgeough the bridge

ough the bridgeough the bridge

ough the bridge’’

’’

’s air-scoop opening.s air-scoop opening.

s air-scoop opening.s air-scoop opening.

s air-scoop opening.

3541 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 17

SS

Step 6tep 6

tep 6tep 6

tep 6 (Cont(Cont

(Cont(Cont

(Cont’’

’’

’d.)d.)

d.)d.)

d.)

II

Install Cnstall C

nstall Cnstall C

nstall Caliper and Paliper and P

aliper and Paliper and P

aliper and Padsads

adsads

ads

Install the caliper onto the adapter bracket, ori-

enting it so that the bleed screws are positioned

on the top side of the caliper.

Slidethe brake padsintoposition within thecali-

per, taking care to ensure that the friction side of

each pad is facing the rotor.

(Y(Y

(Yes, thees, the

es, thees, the

es, theyy

yy

y’’

’’

’vv

vv

ve been installed backware been installed backwar

e been installed backware been installed backwar

e been installed backward beford befor

d beford befor

d before!)e!)

e!)e!)

e!)

Take care to ensure that the caliper is square and

evenlystartedonbothstuds. Itmaybenecessary

touseamallettogently tap the caliper into posi-

tion.

Install a Jet nut onto each stud, with a 12mm

washer under each nut. Tighten the Jet nuts to

40 lb-ft40 lb-ft

40 lb-ftoftorque,usinga 1/2” wrench orsocket.

Apply a light film of anti-seize compound onto

the bridge bolt shafts and threads.

3541 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 18

SS

Step 6tep 6

tep 6tep 6

tep 6 (Cont(Cont

(Cont(Cont

(Cont’’

’’

’d.)d.)

d.)d.)

d.)

II

Install Cnstall C

nstall Cnstall C

nstall Caliper and Paliper and P

aliper and Paliper and P

aliper and Padsads

adsads

ads

NN

Note: The bridge is dirote: The bridge is dir

ote: The bridge is dirote: The bridge is dir

ote: The bridge is directional, and shouldectional, and should

ectional, and shouldectional, and should

ectional, 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

located in the bottom half of the bridge.located in the bottom half of the bridge.

located in the bottom half of the bridge.

Install the bridge by sliding it into position, and

rocking it until one of the bolt holes lines up.

Take careto ensurethatthebridgeisslidstraight

and parallel into the caliper body opening.

Torque each bolt to apprappr

apprappr

approo

oo

oximately 8-10 lb-ftximately 8-10 lb-ft

ximately 8-10 lb-ftximately 8-10 lb-ft

ximately 8-10 lb-ft,

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

Warar

arar

arning: Dning: D

ning: Dning: D

ning: Do not hammer the bridge boltso not hammer the bridge bolts

o not hammer the bridge boltso not hammer the bridge bolts

o not hammer the bridge bolts

into place. Tinto place. T

into place. Tap 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!

Double-check the orientation of the bridge, to

ensure that the air-scoop opening is located in

the bottom half of the bridge.

Start the second bolt, and apply pressure to the

bridge, using the palm of your hand, or by gen-

tly tapping the bridge with a mallet, until the

boltengagesinthehole. Startthefirstfewthreads,

using a 5mm Allen wrench.

Insert the first bridge bolt, from the outside of

thecaliper,and startthe first few threads,using a

5mm Allen wrench.

3541 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 19

SS

Step 7tep 7

tep 7tep 7

tep 7

AA

Attach Sttach S

ttach Sttach S

ttach Stainless Stainless S

tainless Stainless S

tainless Steel Bteel B

teel Bteel B

teel Brake Linerake Line

rake Linerake Line

rake Line

Install the caliper end of the stainless steel brake

line by first placing a copper crush washer on

eithersideofthebanjofitting,theninserting the

banjo bolt into the fitting.

Copper Banjo bolt

Insertthebanjo bolt into the caliper,anglingthe

banjofitting so that it is leaningslightlyforward.

NN

Note: Dote: D

ote: Dote: D

ote: Do not use a toro not use a tor

o not use a toro not use a tor

o not use a torque wrque wr

que wrque wr

que wrench, as oench, as o

ench, as oench, as o

ench, as ovv

vv

ver-er-

er-er-

er-

tightening the bolt can strip the aluminumtightening the bolt can strip the aluminum

tightening the bolt can strip the aluminum

threads, causing irreparable damage to thethreads, causing irreparable damage to the

threads, causing irreparable damage to the

calipercaliper

caliper..

..

.

Torque the banjo bolt to apprappr

apprappr

approo

oo

oximately 14 lb-ximately 14 lb-

ximately 14 lb-ximately 14 lb-

ximately 14 lb-

ftft

ft, using a 14mm wrench or socket.

Use an 11/16” wrench to hold the stainless line

fitting, while using a 13mm flare wrench to

tighten the hard line fitting.

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.

Aftersecuringthebrakeline,turn thewheelslock-

to-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.

3541 UnitA, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799

www.stoptech.com 20

SS

Step 7tep 7

tep 7tep 7

tep 7 (Cont(Cont

(Cont(Cont

(Cont’’

’’

’d.)d.)

d.)d.)

d.)

AA

Attach Sttach S

ttach Sttach S

ttach Stainless Stainless S

tainless Stainless S

tainless Steel Bteel B

teel Bteel B

teel Brake Linerake Line

rake Linerake Line

rake Line

Reinstall the line-retaining spring clip, to secure

the stainless brake line in place.

Take careto ensurethatthe prongsonthe spring

clip are seated within the recesses on the brake

line fitting, then use a mallet to gently tap the

spring clip into place.

StopTech ST-40 Caliper User manual

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