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Installation Instructions
Corvette C5
1997 - 2004
355mm Front
Big Brake Upgrade
ST-40 Caliper
98-180-1470 Rev. C 03-02-06
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C COMPONENT IDENTIFICA OMPONENT IDENTIFICATION TION C C COMPONENT IDENTIFICA OMPONENT IDENTIFICA OMPONENT IDENTIFICATION TION TION 355mm AeroRotor and Hat Assembly ST-40 Caliper Stainless Braided Brake Line and Hardware Caliper Bracket High-Performance Street Pads B B B B Big B ig B ig B ig B ig Brake K rake K rake K rake K rake Kit for the Cor it for the Cor it for the Cor it for the Cor it for the Corv v v v vette C5 ette C5 ette C5 ette C5 ette C5 (This is a representative photograph. The
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APPLICA APPLICA APPLICA APPLICA APPLICATION DISCL TION DISCL TION DISCL TION DISCL TION DISCLAIMER AIMER AIMER AIMER AIMER Caliper Clearance Caliper Clearance Caliper Clearance Caliper 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
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APPLICA APPLICA APPLICA APPLICA APPLICATION DISCL TION DISCL TION DISCL TION DISCL TION DISCLAIMER (Cont AIMER (Cont AIMER (Cont AIMER (Cont AIMER (Cont’’’’’d.) d.) d.) d.) d.) B B B B Brake N rake N rake N rake N rake Noise oise oise oise 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 r
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I I I I Impor mpor mpor mpor mportant N tant N tant N tant N tant Notices otices otices otices otices Wheel Fitment Wheel Fitment Wheel Fitment Wheel 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 www www www www 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
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Cor Corv vette C5 F ette C5 Fr ront Axle K ont Axle Kit it Cor Cor Corv v vette C5 F ette C5 F ette C5 Fr r ront Axle K ont Axle K ont Axle Kit it it Note: It is important to read and understand this ENTIRE installation manual, including Note: It is important to read and understand this ENTIRE installation manual, including Note: It is important to read and understand this ENTIRE installation manual, including Note: It is important to read and understand this ENTIRE installation manual, incl
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Step 1 Step 1 Step 1 Step 1 Step 1 R R Raise aise aise V V Vehicle, and R ehicle, and R ehicle, and Remo emo emov v ve e e Wheels Wheels Wheels R Raise aise V Vehicle, and R ehicle, and Remo emov ve e Wheels Wheels N 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. N N Note: All photographs show a
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Step 2 Step 2 Step 2 Step 2 Step 2 Disconnect Stock Brake Line Disconnect Stock Brake Line Disconnect Stock Brake Line Disconnect Stock Brake Line Disconnect Stock Brake Line W W W W War ar ar ar arning: B ning: B ning: B ning: B ning: Br r r r rake fluid will damage most painted sur ake fluid will damage most painted sur ake fluid will damage most painted sur ake fluid will damage most painted sur ake fluid will damage most painted surfaces. I faces. I faces. I faces. I faces. Immedia
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Step 3 Step 3 Step 3 Step 3 Step 3 R R Remo emo emov v ve S e S e Stock C tock C tock Caliper & R aliper & R aliper & Rotor otor otor R Remo emov ve S e Stock C tock Caliper & R aliper & Rotor otor Remove the two stock caliper bolts, using a 21mm wrench or socket, and retain the bolts for later use. N N N N Note: F ote: F ote: F ote: F ote: Factor actor actor actor actory-installed caliper bolts may be y-installed caliper bolts may be y-installed caliper bolts may be y-installed caliper bol
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S Step 4 tep 4 S S Step 4 tep 4 tep 4 Install Caliper Bracket Install Caliper Bracket Install Caliper Bracket Install Caliper Bracket 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
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S Step 5 tep 5 S S Step 5 tep 5 tep 5 Install AeroRotor Assembly Install AeroRotor Assembly Install AeroRotor Assembly Install AeroRotor Assembly Install AeroRotor Assembly AeroRotors MUST MUST MUST MUST 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 imp
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S Step 5 tep 5 (Cont (Cont’’d.) d.) S S Step 5 tep 5 tep 5 (Cont (Cont (Cont’’’d.) d.) d.) Install AeroRotor Assembly Install AeroRotor Assembly Install AeroRotor Assembly Install AeroRotor Assembly 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
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Left-Side Rotor Outboard Side Outboard Side Outboard Side Outboard Side Outboard Side D D D D Driv riv riv riv river er er er er’’’’’s Left s Left s Left s Left s Left Right-Side Rotor Outboard Side Outboard Side Outboard Side Outboard Side Outboard Side D D D D Driv riv riv riv river er er er er’’’’’s Right s Right s Right s Right s Right 3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
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3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799 www.stoptech.com 14
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C C C C Caliper Component I aliper Component I aliper Component I aliper Component I aliper Component Identification dentification dentification dentification dentification Use a light film of anti-seize on the bridge bolt shafts and threads 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:
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S Step 6 tep 6 S S Step 6 tep 6 tep 6 I I Install C nstall C nstall Caliper and P aliper and P aliper and Pads ads ads I Install C nstall Caliper and P aliper and Pads ads N N N N Note: The images in this section may not be of the v ote: The images in this section may not be of the v ote: The images in this section may not be of the v ote: 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 the ehicle noted, but the ehicle note
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S Step 6 tep 6 (Cont (Cont’’d.) d.) S S Step 6 tep 6 tep 6 (Cont (Cont (Cont’’’d.) d.) d.) I I Install C nstall C nstall Caliper and P aliper and P aliper and Pads ads ads I Install C nstall Caliper and P aliper and Pads 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. Take care to ensure that the caliper is square and evenly started on both studs. It may be necessary to use a mallet to gently tap the calipe
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S Step 6 tep 6 (Cont (Cont’’d.) d.) S S Step 6 tep 6 tep 6 (Cont (Cont (Cont’’’d.) d.) d.) I I Install C nstall C nstall Caliper and P aliper and P aliper and Pads ads ads I Install C nstall Caliper and P aliper and Pads ads Install the bridge by sliding it into position, and rocking it until one of the bolt holes lines up. Take care to ensure that the bridge is slid straight and parallel into the caliper body opening. N N Note: The bridge is dir ote: The bridge is dir ote: The bridge is dire
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S Step 7 tep 7 S S Step 7 tep 7 tep 7 A A Attach S ttach S ttach Stainless S tainless S tainless Steel B teel B teel Brake Line rake Line rake Line A Attach S ttach Stainless S tainless Steel B teel Brake Line rake 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 fitting. Copper Banjo bolt Insert the banjo bolt into the caliper, angling the banjo fitting so that it is
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S Step 7 tep 7 (Cont (Cont’’d.) d.) S S Step 7 tep 7 tep 7 (Cont (Cont (Cont’’’d.) d.) d.) A A Attach S ttach S ttach Stainless S tainless S tainless Steel B teel B teel Brake Line rake Line rake Line A Attach S ttach Stainless S tainless Steel B teel Brake Line rake Line Reinstall the line-retaining spring clip, to secure the stainless brake line in place. Take care to ensure that the prongs on the spring clip are seated within the recesses on the brake line fitting, then use a mallet to gently
