Installation Instructions
Corvette C5
1997 - 2004
355mm Front
Big Brake Upgrade
ST-40 Caliper
98-180-1470
Rev. C 03-02-06
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’ 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 support@stoptech.com.
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 (310) 325-4799
3
APPLICATION DISCLAIMER (Cont’d.)
Brake Noise
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.
Note: The customer is responsible for any squeal-related problems due to pad selection.
Permanent Modification to Lower Ball Joints
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.
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 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
support@stoptech.com.
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 associ-
ated nor affiliated with, nor sponsored by General Motors.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
4
Important Notices
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 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 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.
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
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 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 installa-
tion 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-
performance 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 (310) 325-4799 - extension 105, or you can
e-mail directly to support@stoptech.com.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
5
Corvette C5 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 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
Tools and Equipment Required
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-
sionally, however, manufacturers use alternate fasteners, 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:
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 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
6
Step 1
Raise Vehicle, and Remove Wheels
Note: All photographs show a right-hand side installation, unless otherwise noted.
A level, stable and clean surface, suitable for sup-
porting 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 vehicle.
Jack up the vehicle, and secure it on a pair of
jack-stands, referring to the owner’s manual to
identify the correct jack and support locations.
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.
If necessary, place a wheel nut on one of the
studs, to prevent the rotor from falling.
To make it easier to access the brake line fittings,
turn the steering either toward or away from the
side that you’re working on, depending on the
orientation of the caliper.
If you’re installing a leading caliper, turn the
steering toward the side that you’re working on,
and if you’re installing a trailing caliper, turn
the steering away from the side that you’re work-
ing on. This will make access to the caliper bolts
easier.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
7
Step 2
Disconnect Stock Brake Line
Warning: Brake fluid will damage most painted surfaces. Immediately clean spilled brake
fluid from any painted surface. Also be sure that the cap is securely installed on the master
cylinder. If the cap is loose or removed, it is likely that more fluid will drip during brake
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.
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.
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.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
8
Step 3
Remove Stock Caliper & Rotor
Remove the two stock caliper bolts, using a 21mm
wrench or socket, and retain the bolts for later
use.
Note: Factory-installed caliper bolts may be
very tight. Ensure that you have a good pur-
chase on the bolt head, and that you are in a
good position to turn the wrench or socket.
Remove the caliper with the stock brake line at-
tached. There may be some leakage from the
open end of the brake line, especially if the pads/
pistons on the caliper are retracted.
Remove the stock rotor, by pulling it off of the
hub by hand.
Note: It may be necessary to strike the outer
edge of the rotor with a non-marring mallet,
if corrosion prevents the rotor from simply
being pulled off. If so, place a wheel bolt in
one of the holes first, to prevent the rotor
from falling when it comes loose.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
9
Step 4
Install Caliper Bracket
Remove the Jet nuts and washers from the caliper
mounting bracket, and put them aside for later
use.
Place a few drops of the supplied Loctite 262 on
the threads of each stock caliper bolt.
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.
Tighten the caliper bracket bolts, using a 21mm
wrench or socket, then torque the bolts to 125
lb-ft.
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
10
Step 5
Install AeroRotor Assembly
AeroRotors 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.
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
performance of your new brake system.
Warning: Do not skip this step!
Install the hat and rotor assembly, ensuring that
the rotor is seated squarely on the hub face. If
necessary, clean the face of the hub, using a 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.
Note: Take care to ensure that the rotor assembly is on the correct side of the car, as reversing
the rotors will severely decrease the cooling capacity of the system. The rotors are clearly
marked “L” and “R” with orange tags on the rotor hats. If the tags are not legible, the vanes
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).
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
11
Step 5 (Cont’d.)
Install AeroRotor Assembly
It may be necessary to clearance the lower ball
joint slightly, to clear the inboard face of the
AeroRotor during full suspension travel. A coarse
file can remove the material, although a power
grinder is more efficient, if used properly.
Install the rotor, and check the proximity of the
lower ball joint to the inner rotor face. Turn the
wheel lock-to-lock, to determine how far around
the front and back edge needs to be clearanced.
Note: If only the lip around the outer ridge is
removed, the structural integrity of the lower
ball joint will not be compromised. If you are
not comfortable making this modification, seek
the help of a qualified professional.
Remove the lip which protrudes around the outer
edge of the ball joint (the approximate area is
shown in the photograph to the left).
Ridge Width
Remove ridge in this area
With the suspension at FULL DROOP, there
should be a clearance of 3.5 - 4.8mm (1/8 - 3/16)
between the inner face of the rotor and the outer
diameter of the lower ball joint.
3.5 - 4.8mm
at full droop
3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
12
|