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Installation Instructions
2000+ BMW E39
M5 and 5-Series
355mm Rear
Big Brake Upgrade
ST-40 Caliper
98-135-1471 Rev. A 12-10-04
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C C C C COMPONENT IDENTIFICA OMPONENT IDENTIFICA OMPONENT IDENTIFICA OMPONENT IDENTIFICA OMPONENT IDENTIFICATION TION TION TION TION AeroRotor and Hat Assemblies High-Performance Street Pads Caliper Brackets Calipers Stainless Steel Braided Lines and Hardware BMW E39 M5 and 5-Series Rear Big Brake Kit BMW E39 M5 and 5-Series Rear Big Brake Kit BMW E39 M5 and 5-Series Rear Big Brake Kit BMW E39 M5 and 5-Series Rear Big Brake Kit BMW E39 M5 and 5-Series Rear Big Brake Kit This is a representati
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APPLICA APPLICA APPLICA APPLICA APPLICATION DISCL TION DISCL TION DISCL TION DISCL TION DISCLAIMER AIMER AIMER AIMER AIMER P P Per er ermanent R manent R manent Remo emo emov v val of D al of D al of Dust S ust S ust Shield hield hield P Per ermanent R manent Remo emov val of D al of Dust S ust Shield hield The dust shield must be permanently removed from both rear wheels of the vehicle, to accommodate the AeroRotors. This involves cutting each shield with sheet metal snips or a power cut-off w
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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.) Wheel S Wheel Spacers pacers Wheel S Wheel S Wheel Spacers pacers pacers 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 low- ered cars, and longer lug studs or wheel bol
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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 F Wheel F Wheel Fitment itment itment Wheel F Wheel Fitment itment Do not assume that your wheels will fit. An outline drawing of your StopTech Big Brake kit is available on 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 face of your wheel spokes, or make
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BMW E39 M5 and 5-Series Rear Axle Kit BMW E39 M5 and 5-Series Rear Axle Kit BMW E39 M5 and 5-Series Rear Axle Kit BMW E39 M5 and 5-Series Rear Axle Kit BMW E39 M5 and 5-Series Rear Axle Kit N N Note: I ote: I ote: It is impor t is impor t is important to r tant to r tant to read and understand this ENTIRE installation manual, including the ead and understand this ENTIRE installation manual, including the ead and understand this ENTIRE installation manual, including the N Note: I ote: It is
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S S S S Step 1 tep 1 tep 1 tep 1 tep 1 R Raise aise V Vehicle, and R ehicle, and Remo emov ve e Wheels Wheels 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 N N N N Note: A ote: A ote: A ote: A ote: All photogr ll photogr ll photogr ll photogr ll photographs sho aphs sho aphs sho aphs sho aphs show a right-hand side installation, unless other w a right-hand side installation, unless other w a right-hand side installation, unless
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S S S S Step 2 tep 2 tep 2 tep 2 tep 2 D Disconnect S isconnect Stock B tock Brake Line rake Line D D Disconnect S isconnect S isconnect Stock B tock B tock Brake Line rake Line rake 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 fa
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S S S S Step 3 tep 3 tep 3 tep 3 tep 3 R Remo emov ve S e Stock C tock Caliper & R aliper & Rotor otor R R Remo emo emov v ve S e S e Stock C tock C tock Caliper & R aliper & R aliper & Rotor otor otor Carefully remove the stock pad-wear sensor from the caliper, and place it out of the way tempo- rarily, so that it will not be damaged. N Note: T ote: Take car ake care to ensur e to ensure that the metal clip e that the metal clip N N Note: T ote: T ote: Take car ake car ake care to ensur e
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S S S S Step 4 tep 4 tep 4 tep 4 tep 4 R Remo emov ve D e Dust S ust Shield hield R R Remo emo emov v ve D e D e Dust S ust S ust Shield hield hield The dust shield must be permanently removed from both rear wheels of the vehicle, to accommodate the AeroRotors. This involves cutting each shield with sheet metal snips or a power cut-off wheel, and de-burring sharp edges with a file or power die grinder. W W War ar arning: These oper ning: These oper ning: These operations can be danger ations
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S S S S Step 5 tep 5 tep 5 tep 5 tep 5 Install Caliper Bracket Install Caliper Bracket Install Caliper Bracket Install Caliper Bracket Install Caliper Bracket Remove the jet nuts and washers from the caliper bracket, and put them in a safe place for later use. Install the caliper bracket, using a 16mm wrench or socket to tighten the stock caliper mounting bolts. Torque the bolts to 50-55 lb-ft 50-55 lb-ft 50-55 lb-ft. 50-55 lb-ft 50-55 lb-ft 3541 Unit A, Lomita Boulevard, Torr
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S S S S Step 6 tep 6 tep 6 tep 6 tep 6 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 (soap and warm water work best to remove all traces of rust inhibitor, but brake cleaner can be used as an alternative, if necessary). Not cleaning the AeroRotors will damage the rotors and pads, and will prevent the brakes from performi
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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 Pad-retaining Clip Bolt-in Bridge Cross Over Tube Bridge Bolts Bleed Screw Use a light film of anti-seize compound on the bridge bolt shafts and threads The ST-40 original equipment caliper uses a pad that is common to two-piston opposed calipers. The Friction Materials Standards Institute (FMSI) number for the pad backing pl
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S S S S Step 7 tep 7 tep 7 tep 7 tep 7 I Install C nstall Caliper and P aliper and Pads ads I I Install C nstall C nstall Caliper and P aliper and P aliper and Pads ads ads Note: The images in this section may not be of the vehicle noted, but they give a proper Note: The images in this section may not be of the vehicle noted, but they give a proper Note: The images in this section may not be of the vehicle noted, but they give a proper Note: The images in this section may not be of the vehic
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S S S S Step 7 (Cont tep 7 (Cont tep 7 (Cont tep 7 (Cont tep 7 (Cont’’’’’d.) d.) d.) d.) d.) I Install C nstall Caliper and P aliper and Pads ads I I Install C nstall C nstall Caliper and P aliper and P aliper and Pads ads ads Install the stainless steel brake line onto the cali- per, using a 14mm wrench to tighten the line fitting. Install the caliper onto the adapter bracket, ori- enting it so that the bleed screws are on the top side of the caliper. Take care to ensure that the caliper is squ
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S S S S Step 7 (Cont tep 7 (Cont tep 7 (Cont tep 7 (Cont tep 7 (Cont’’’’’d.) d.) d.) d.) d.) I Install C nstall Caliper and P aliper and Pads ads I I Install C nstall C nstall Caliper and P aliper and P aliper and Pads ads 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 N N Note: The bridge is dir ote: The bridge is dir ote: The bridge i
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S S S S Step 8 tep 8 tep 8 tep 8 tep 8 A Attach S ttach Stainless S tainless Steel B teel Brake Line rake Line A A Attach S ttach S ttach Stainless S tainless S tainless Steel B teel B teel Brake Line rake Line rake Line Reinsert the rubber washers on either side of the inboard brake line bracket, then remove the rubber cap from the hard line, and screw the stainless steel brake line onto the hard line fit- ting by hand for a few turns. Use a 14mm wrench to hold the stainless line inboard fittin
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S S S S Step 9 tep 9 tep 9 tep 9 tep 9 Bleed Brakes Bleed Brakes Bleed Brakes Bleed Brakes Bleed Brakes Complete the installation on both sides of the vehicle before bleeding the system. W W W W War ar ar ar arning: D ning: D ning: D ning: D ning: Double-check that the stainless steel br ouble-check that the stainless steel br ouble-check that the stainless steel br ouble-check that the stainless steel br ouble-check that the stainless steel brake lines y ake lines y ake lines y ake lines y
