StopTech Automobile Accessories 98-139-1470 User's Manual
Contents
1. support stoptech com Thank VOU for selecting StopTech we realize you had a choice in selecting a big brake upgrade for your vehicle and know you ll be happy with our system We proudly support our fine products For any assistance or guestions please contact our Customer Service Departmant at 310 325 4799 extension 105 or e mail us at support stoptech com HIGH PERFORMANCE BRAKE SYSTEMS2. 541 Unit A Lomita Boulevard Torrance CA 90505 310 325 4799 www stoptech com 7 Step 3 Remove Stock Caliper 8 Rotor Note It is helpful to turn the steering away from the side you are working on so the wrench handle clears the rear of the wheel well The Z8 has a pad wear sensor on the left front and right rear corners These sensors can be carefully removed from the stock brake pad and re inserted into the new pad in the StopTech ST 40 caliper You will likely need to re route the lead wire which can typically be ty wrapped to the new brake line Remove the two stock caliper bolts with an 18mm wrench or socket Set these bolts aside for use in a later step Caliper bolts may be very tight from the factory Ensure that you have a good purchase on the head of the bolt and are in a good position to turn the wrench or socket Remove the caliper with 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 Th Remove the stock rotor by first removing the retaining bolt with a 6mm Allen wrench It may be necessary to strike the outer edge with a non marring hammer if corrosion prevents the rotor from simply pulling off If so place 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 www stoptech com 8 Step 4 Re
3. Installation Instructions 2000 BMW Z8 355mm Front Big Brake Upgrade Ld HIGH PERFORMANCE BRAKE SYSTEMS 98 139 1470 Rev 03 12 03 COMPONENT IDENTIFICATION 355mm AeroRotor and Hat Assemblies Performance Street Pads rs I gt ST 40 Calipers gt i Stainless Braided Lines and Hardware BMW 78 Big Brake Kit This is a representative photograph The actual com ponents in your kit may appear slightly different 3541 Unit A Lomita Boulevard Torrance 90505 310 325 4799 www stoptech com 2 APPLICATION DISCLAMER Caliper Clearance Most 18 wheels will clear the outer diameter of the caliper on a 355mm kit However the more critical clearance is the gap between the spokes of the wheel and the face of the caliper Do not assume a 19 20 or even 24 inch wheel will clear the face of the caliper The actual metal to metal distance measured from the stock rotor face to the inside of the wheel spokes is 58 72 mm for the Z8 Front kit We recommend at least 2mm of additional clearance See the Wheel Fitment Drawing page on our website for more specific measurements at www stoptech com 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
4. Unit A Lomita Boulevard Torrance CA 90505 310 325 4799 www stoptech com Caliper Component Identification Bolt in Bridge Pad Retaining Clip Cross Over Tube Bridge Bolts Bleed Screw Use a light film of Anti Sieze on Bridge Bolt shaft and threads The ST 40 caliper uses a Porsche style pad The Friction Materials Standards Institute FMSI number for the pad backing plate is D372 Please see the FAQ section of our website for further pad interchange information www stoptech com 15 Step 7 Install Caliper and Pads Determine the left and right side calipers The calipers are marked on each box As a check the bleed screws always go to the top of the caliper Remove the 2 bolts holding the caliper bridge using a 5mm Allen wrench Remove the caliper bridge taking note of the direction it is installed in and the correct location of the pad retaining wire clip which typically but not always stays attached to the bridge Bridge Bolts In order to stiffen the caliper the bridge is a snug fit and the bolts may be tight when removing Keep turning 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 with a plas tic or leather hammer or similar tool The handle of a tool works well for this With use the bridge and bolt will become easier to remove and install 3541 Unit A Lomita Boulevar
5. d Torrance CA 90505 310 325 4799 www stoptech com 15 Step 7 Continued Note Images on this and the following page may not be of the vehicle noted however they are a proper represention of the correct installation r Install the caliper onto the adapter bracket studs with the bleed screws on the top side of the caliper ml 1 E Slide the caliper over the mounting studs making sure it is sguare and evenly started on both studs It may necessary to gently tap the caliper into position with a non marring hammer or mallet Install the Jet nuts onto each stud with one 12mm washer under each nut Tighten the Jet nuts to 40 45 lb ft of torque using a 1 2 socket Slide the brake pads into position in the calipers Be sure the friction side of each pad is facing the rotor Yes they have been installed backward before 3541 Unit A Lomita Boulevard Torrance CA 90505 310 325 4799 www stoptech com 16 Step 7 continued Install the bridge by sliding it into position and rocking it until one of the bolt holes lines up Be sure the bridge is slid straight and parallel into the caliper body opening Note The bridge is directional and the air scoop detail should face down on the Supra kit Apply a light film of anti sieze compound onto the bridge bolt shaft and threads Insert the first bridge bolt and start the first few threads using a 5mm Allen wrench Gently press the opposite side of t
6. d in such environments applications are subject to stresses and condi tions outside of normal use wear and tear All equipment sold or provided by Stop Tech LLC is sold WITHOUT WARRANTY EXPRESSED OR IMPLIED No warranty or representation is made to the products ability to protect the user from injury or death The user assumes all risk Stop Tech LLC is NOT responsible for any damage consequential or otherwise for equipment failure or mal performance after installation Under no circumstance are we liable for labor charges or loss of use Tools and Equipment Required Note Some different models or years may use different size fasteners Every effort has been taken to correctly identify the proper size tool for each job Occasionally the manufacturer may use an alternate fastener Check that each tool correctly fits the fastener before loosening or tightening 18mm wrench or socket 1 2 drive suggested 14mm wrench or socket 11mm box wrench in addition an 11 flare wrench is also recommended 10mm wrench or socket Gmm Allen hex wrench 1 2 socket Torque wrenches capable of 10 85 ft lb settings Small drip tray or several rags Small funnel Anti Sieze compound Brake bleed bottle 1 pair of jack stands or means of supporting vehicle Plastic or non marring mallet File or hand grinder 3541 Unit A Lomita Boulevard Torrance CA 90505 310 325 4799 www stoptech com 5 DOT 3 or 4 Brake Fluid Check manufactures recommenda
7. e cooled After the break in cycle is finished there will be a blue tint color on the rotor with a light gray film on the rotor face The blue tint indicates the rotor has reached the proper break in temperature and the gray film is pad material starting to transfer onto the rotor face This is normal and good If racing or higher performance pads are being used add four stops from 80 to 5 10mph and if a full race pad four stops from 100 to 5 10 mph After the first break in cycle shown above the brakes will still not be operating at their best capacity A second or third bed in cycle is typically necessary before the brakes really start to come in A cycle is a series of stops with a cool down in between each cycle Stop Tech does not endorse speeding on public roads If going above the legal speed limit do so in a safe area away from traffic at your own risk After the final stop of each cycle drive 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 again DO NOT COME TO A COMPLETE STOP WHEN THE SYSTEM IS HOT AND LEAVE YOUR FOOT ON THE PEDAL PAD MATERIAL WILL IMMEDIATELY TRANSFER TO THE ROTOR CAUSING A VIBRATION If you have any questions about rotor and pad break or any aspect of your Stop Tech brake kit or brakes in general please contact our Customer Service Department at 310 325 4799 X 105 or e mail us at
8. e use A non plated rotor looks like bare metal plated rotors are bright silver in color and do not need to be washed Even though you may not see a change in the rotor color if the rotor is not rusty the rust inhibitor is there Use soap and water BRAKE CLEANER to wash the rotors A small piece of Scothbrite works well to scrub with When cleaned and rinsed properly the surface of the rotor will immediately show a light rust color which is normal Break in your new pads and rotors by carefully fol lowing the procedure described below and on the opposite side of this page Breaking rotors and pads is critical to the optimum performance of your new brakes When breaking in new parts you are not only heat cycling the pads but depositing a layer of pad material onto the rotor face as well If not broken in properly an uneven layer of pad material will be depos ited onto the rotor causing vibration Virtually every instance of a warped rotor is attributed to uneven pad deposition Note Plated rotors must be driven with gentle braking until CAD plating is worn off rotor faces BEFORE starting the break in procedure Do not use brakes aggressively until plating is worn off typically several miles of driving Typically a heavy braking street driver will experience approximately 1 to 1 1G s of deceleration At this rate ABS will be activated on such equipped vehicles A moderate braking effort is needed to properly break in r
9. emove wheels Apply Parking brake and block rear wheels Break loose the lug nuts on both front wheels before jacking up the car Refer to the Owners Manual for correct location for jacking up the vehicle Jack up the vehicle and secure on a pair of jack stands NEVER LEAVE ANY VEHICLE SUPPORTED WITH ONLY A JACK ALWAYS USE JACK STANDS 3541 Unit A Lomita Boulevard Torrance 90505 310 325 4799 www stoptech com 6 Step 1 continued Note All Photographs Show Right Side Installation Unless Noted Otherwise After securing the vehicle at a convenient height remove the front wheels Step 2 Disconnect Stock Brake Line WARNING Brake fluid will damage most painted surfaces Immediately clean spilled brake fluid from any painted surfaces Note Be sure the cap is securely installed on the master cylinder If the cap is loose or removed it is likely more fluid will drip 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 and strut is dirty clean with brake cleaner or appropriate cleaning agent Use an 11mm wrench to slightly loosen the hard line fitting from the stock brake line Switch to an 11mm stubby wrench if available and remove the rubber line from the hard line Place one of the rubber caps over the end of the hard line This should effectively control fluid loss for the duration of the installation 3
10. en removed Rotor and Pad Break in Proper rotor and pad break in is essential to the performance of your new brake system Failure to properly break in the brakes will seriously impact how well they work and how long they last The number one cause of brake vibration is uneven pad material deposition on the rotor Proper break in will greatly minimize such prob lems Follow the break in procedures listed later in this manual as closely as possible If you have any guestions about wheel fitment rotor cleaning or break in of a particular pad type please call our Customer Service Department 2 310 325 4799 X 105 or you can e mail directly to support stoptech com BMW 78 Front Axle Kit Please believe us it will be better to read and understand this ENTIRE Installation Manual including the included Break in Procedures before starting the installation 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 as 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 street is dangerous Products use
11. g into the new brake line by hand for a few turns before tightening with an 11mm flare wrench Use a 14mm wrench to hold the stainless line inboard fitting while using the flare wrench to tighten the hard line fitting Note It may help to have the wheels straight to access the fittings with the wrenches After securing the line turn the wheels lock to lock to make sure the line is not binding of touching any moving parts of the suspen sion Adjust as necessary by re clocking the Banjo bolt on the caliper The Z8 has a pad wear sensor on the left front and right rear corners These sensors can be carefully removed from the stock brake pad and re inserted into the new pad in the StopTech ST 40 caliper You will likely need to re route the lead wire which can typically be ty wrapped to the new brake line 3541 Unit A Lomita Boulevard Torrance CA 90505 310 325 4799 www stoptech com 18 Step 9 Bleed Brakes Complete installation on both sides of the vehicle before bleeding the system Note The calipers and lines will need to fill with fluid quickly draining the master cylinder reser voir Keep a close watch on the fluid level when initially bleeding the system Do not allow the master cylinder reservotr to run dry and draw in air Doing so may require the brake system to be serviced by a certified brake technician Bleed the brake system using an 11mm wrench on the bleed screws The sequence for bleeding the brakes
12. g is washing off the rust inhibitor is in place and must be removed Not cleaning the rotors will severely impact the perfor mance of q your new brake system Scrubbing AeroRotor with ScotchBrite pad soap and water Do not skip this step 3541 Unit A Lomita Boulevard Torrance CA 90505 310 325 4799 www stoptech com 10 Step 6 continued Install hat and rotor assembly and hold in place with the stock retaining fastener Be sure rotor is seated squarely on hub face If necessary clean the face of the hub with a wire brush or similar means Be sure the rotor assemblies are on the correct side of the car Reversing the rotors will severely decrease the cooling capac ity 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 12 amp 13 for more detailed images 3541 Unit A Lomita Boulevard Torrance CA 90505 310 325 4799 www stoptech com 11 Left Side Rotor Outboard Side k a j z Driver s Left Right Side Rotor Outboard Side Wi PO r A 4 gt i po P OR Driver s Right 3541 Unit A Lomita Boulevard Torrance CA 90505 310 325 4799 www stoptech com 12 RIGHT SIDE SHOWN 3541
13. he bridge with the palm of your hand or tap with a mallet until the second bolt engages the hole With pressure still applied start the second bolt Torque each bolt to 8 10 lb ft DO NOT OVER TORQUE BRIDGE BOLTS Snug is tight enough If the fit of the bridge into the caliper is tight it may be necessary to tap into position with a mallet While applying pressure to the bolt head adjust the position of the bridge until the bolt slides more freely into place WARNING DO NOT HAMMER BRIDGE BOLTS INTO PLACE BRIDGE NOT BOLTS Apply pressure to head of bolt If necessary apply pressure on bridge to posi tion properly Do not hammer bridge too deep into the caliper as you may deform the pad retaining spring clip 3541 Unit A Lomita Boulevard Torrance 90505 310 325 4799 www stoptech com 17 Step 8 Attach the stainless brake line Install the banjo bolt into the caliper with a copper crush washer on each side of the Banjo fitting Route the line vertically approximately parallel with the caliper body wa Copper Crush Washers Banjo Bolt Torque to approximately 14 lb ft using a 14mm wrench 4 The Banjo bolt only needs to be tightened enough to seal the crush washers Excessive torque can damage the threads inside the caliper and or damage the Banjo bolt Place the stainless steel washer over the inboard brake line fitting as shown Remove the rubber cap from the hard line and screw the fittin
14. heel manufacturer s specifications It may be necessary to snug the bolts before lowering the vehicle and 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 drive the vehicle in a safe area at low speed to insure all components are working correctly Then follow pad and rotor break in procedures on following pages All trademarks are properties of their respective owners StopTech LLC is not associated or affiliated with or sponsored by BMW 3541 Unit A Lomita Boulevard Torrance CA 90505 310 325 4799 www stoptech com 20 HIGH PERFORMANCE BRAKE SYSTEMS AeroRotor Installation 82 Break in Procedure READ THIS NOW FAILURE TO READ UNDERSTAND AND FOLLOW THESE PROCEDURES WILL CAUSE PERMANANT DAMAGE TO YOUR BRAKE ROTORS AND KEEP THE SYSTEM FROM WORKING 5 FULL CAPACITY The majority of brake system problems are due to improper installation and or break 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 PERMENANT DAMAGE TO YOUR NEW ROTORS Wash Non Plated AeroRotors with SOAP AND WATER before installation StopTech coats non plated AeroRotors with a water soluable environmentally friendly rust inhibi tor that MUST be cleaned befor
15. lowered cars and longer lug studs or wheel bolts are usually required Note The Wheel Industry Council has issued guidelines advising wheel spacers not be used It is the responsibility of the customer to insure wheel spacers are properly specified and installed Brake Vibration THIS IS IMPORTANT The most common cause of brake vibration is improper bedding of pads and rotors or improper pad selection for the specific driving environment Rotor runout may also cause vibration but precision manufacturing and inspection typically means runout is not an issue Double disc grind ing insures the rotor runout is within 0 002 when installed on our aluminum hat and controls thickness variation within 0 0003 Under the most extreme conditions any rotor may warp but uneven pad deposition is a more typical vibration cause If the system is not properly bedded in or 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 procedures included with this manual If you have any questions please contact the StopTech Customer Service Department for assistance STOPTECH is not liable for vibrations caused by extreme usage or improper break in procedures Brake Noise Certain brake pad compounds make more noise than others Proper anti squeal shim plate
16. move Slash Guard Dust Shield Use a 10mm wrench or socket to remove the four bolts holding the dust shield Step 5 Install Caliper Bracket The brackets are marked amp R for Left and Right sides of the vehicle as viewed from the rear of the vehicle looking forward It may be necessary to slightly clearance the mounting lug on the knuckle This modification in no way compromises the strength of the part Bracket shown attached to knuckle using stock caliper mounting bolts Note studs face to the rear and the bracket is located on the outboard face of the mounting lugs Test fit in this posi tion to determine if the lug needs to be clearanced 3541 Unit A Lomita Boulevard Torrance CA 90505 310 325 4799 www stoptech com 9 Step 5 Install Caliper Bracket continued y File this area 7 If the caliper bracket does not sit flat and the bolts do not line up it may be necessary to file the outer edge of the mounting lugs as shown above The image to the right shows the lower lug noting where to file After proper fit of the bracket has been confirmed install the caliper bracket as shown on the previous page Torque caliper bracket bolts to 80 85 lb ft Step 6 Install AeroRotor Assembly Rotors MUST be cleaned with soap and water prior to installation Not doing so will damage the rotors and pads and prevent the brakes from performing properly Even though it may not look like anythin
17. otors and pads If ABS intervention or lock up was called 100 brake effort a stopping force of approximately 70 80 just short of ABS intervention or lock up is a general estimate of pedal effort you are trying to achieve Please see other side 3541 Unit A Lomita Boulevard Torrance CA 90505 310 325 4799 Document 98 300 0001 Rev I 06 27 02 www stoptech com Rotor and Break in continued Note Bedding of pads should not be done in wet weather or wet road conditions After completeing 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 series of stops the exact speed 15 not critical Accelerate to appoximately 60 and begin the braking cycle As you approach 5 10 MPH it is not necessary to watch the speedometer keep your eyes on the road and approximate your speed at the end of each cycle DO NOT COME TO A COMPLETE STOP AS YOU WILL IMPRINT PAD MATERIAL ONTO THE ROTOR CAUSING A VIBRATION There are several indicators to look for while breaking in the system On the 8th or 9th stop there should be a distinct smell from the brakes Smoke may be evident after several stops as well Also on the 8th or 9th stop some friction materials will experience green fade This is a slight fading of the brakes fade will stabilize but not completely go away until the brakes hav
18. s be tween the caliper pistons and backing plate of the pad help reduce the problem Anti squeal lubri cants are also available to reduce some of the noise The reality is performance pads are more prone to brake squeal The customer is responsible for any squeal related problems due to pad selection 3541 Unit A Lomita Boulevard Torrance CA 90505 310 325 4799 www stoptech com 3 Important Notices Wheel Fitment Do not assume your wheels will fit An outline drawing of your StopTech Big Brake kit is available on our website at http 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 and deter mine if a wheel spacer may be necessary DO THIS BEFORE YOU INSTALL YOUR KIT Cleaning of Rotors The AeroRotors supplied with this kit are coated with a water soluable environmen tally friendly rust inhibitor This coating MUST 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 If the rotor is not rusty it s still coated After cleaning you will see the rotor immediately start to develop a slight rust color This is normal and desirable as it indicates all the rust inhibitor has be
19. should be 1 Right outboard bleed screw 2 Right inboard bleed screw 3 Left outboard bleed screw 4 Left inboard bleed screw Though a torque wrench is typically NOT used on bleed screws as a reference torque for bleed screws should be 100 140 INCH Pounds After initially bleeding the system gently tap the caliper body with a non marring mallet or hammer to dislodge any small air bubbles and re bleed After bleeding apply a constant pressure to the brake pedal and check all connections including bleed screws and both ends of the line for leaks Brake fluid will damage most painted surfaces Immediately clean spilled brake fluid from any painted surface including the caliper Though caliper paint is designed to resist harsh chemicals prolonged exposure will damage the finish 3541 Unit A Lomita Boulevard Torrance 90505 310 325 4799 www stoptech com 19 Step 10 Re install wheels Check wheel to caliper clearance before installing wheels Note Some wheels are balanced on the inside with adhesive backed lead If the lead is on the outboard edge behind the spokes it may interfere with the caliper If necessary note weight and location and place a new piece of the same weight further inboard or outboard to clear the caliper If you rotate tires regularly you should check the wheel weight positions on all four wheels and the spare as well if it is full sized Re install the wheels and torque the lug nuts to your w
20. tion for compatibility Stop Tech recommends flushing brake fluid every 1 2 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 upgrade to a higher performance fluid such as Motul 600 Additional items you may need include Adhesive backed lead wheel weights This kit contains the following 1 pair of ST 40 4 piston calipers sized specifically for the BMW 78 1 set of high performance brake pads 1 pair of 355 X 32mm 2 rotor assemblies 1 pair of aluminum caliper adapter brackets 4ea 7 16 20 Jet Nuts 4ea 12mm washers 1 pair of stainless brake lines 1 pair of Banjo Bolts 2 pair of copper washers 1 pair of rubber end caps 1 pair stainless washers for brake lines Caliper Hat and Bracket Finish Disclaimer Many wheel cleaning solutions contain strong acids that may damage the finish on any caliper and 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 will not be held liable for damage to caliper hat or bracket finish due to corrosive chemical exposure A level stable and clean surface suitable for supporting the car on jack stands should be used for the installation Step 1 Raise Vehicle and r
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