Installation F-150 2WD and Ford Expedition 1999 – 2002

Kit Contents Kit Contents Kit Contents Kit Contents Kit Contents Your StopTech Big Brake kit includes the following:
1 pair of ST-40 four-piston calipers, sized specifically for the 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 hub assemblies
1 pair of stainless steel brake lines
1 pair of Adel clamps
1 pair of 10mm button-head bolts (for use with the Adel clamps)
1 pair of self-locking nuts (for use with the Adel clamps)
1 pair of banjo bolts
2 pair of copper crush washers
1 pair of rubber end caps

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3541 Unit A, Lomita Boulevard, Torrance, CA 90505 (310) 325-4799
http://www.stoptech.com 7
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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. Occasionally, 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:
18mm wrench or socket (1/2” drive suggested)
17mm line wrench
14mm line wrench
11mm box wrench
11mm flare wrench
10mm wrench or socket
1 1/16” socket
1/2” socket (3/8” drive suggested)
5mm Allen (hex) wrench
3mm Allen (hex) wrench
Dust cap removal tool, or large flat-blade screwdriver
Needle-nose pliers
Chisel
Hack saw
Power drill fitted with a #19 bit
Torque wrenches capable of 10-85 lb-ft settings
Small drip tray or several rags
Small funnel or suitable means of filling master cylinder reservoir
Wheel bearing grease
Anti-seize compound
Brake bleed bottle
1 pair of jack stands or other means of supporting vehicle
Plastic or non-marring mallet
DOT 3 or 4 Brake Fluid. Check manufacturer’s recommendation for compatibility. StopTech
recommends flushing brake fluid every one-to-two years, or more often under severe usage condi-
tions. 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.

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 wheel and
the face of the caliper. Do not assume that a larger-diameter wheel will automatically clear the face of
the caliper.

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