How do I install a Big Brake Kit? - SPS Installation Instructions

The braking system is pretty much the most important safety-relevant system in your car. So you should know exactly what is important when installing your brake system. In this post you will find all the information you need to install your new brake system!
First of all, it should be mentioned that we have prepared installation instructions for the StopTech brake systems we offer. In these installation instructions you will find important information such as tightening torques and much more. The installation instructions are stored in our shop on the respective article in the "Downloads" tab.

How do I remove the old brake system?

Of course, we want to assemble and test the new brake system as soon as possible. However, you should take your time with the complete assembly so that all screws are really tight and all lines are tight afterwards. Always wear protective gloves (we use nitrile gloves) and protective goggles when handling brake fluid. We start by loosening the old brake line to the caliper on the vehicle side (where the fixed brake line is connected to the brake hose). So that no brake fluid gets into the environment, the dust cover of the bleeder connection can simply be plugged onto the now open brake line. It is best to place the old brake hose directly in a tub so that no brake fluid can get into the environment and can later be disposed of cleanly.
Then we go on with the brake caliper and its bracket. To do this, simply loosen the screws that connect the caliper bracket and you should be able to remove the caliper from the disc. 
Then all we have to do is remove the brake disc from the wheel hub. If this cannot simply be removed, there are threaded holes in most of the brake discs. Simply screw in a suitable screw here to push the brake disc away from the wheel hub.

Which preparation should I do before installing the Big Brake Kit?

So that the new brake disc sits clean and straight on the wheel hub afterwards, you should now absolutely clean the contact surface on the wheel hub. If you skip this, you will definitely have problems with vibrations when braking or, in the worst case, a reduced braking effect. A wire brush or a special attachment for the cordless screwdriver is ideal for cleaning the wheel hub.
Now you can place the new brake disc on the cleaned wheel hub and see whether the dust shield needs to be processed. This must be processed in any case if the diameter of the new brake disc is larger than the diameter of the old brake disc (e.g. NA / NB before 235 / 255 / 270mm, afterwards 280mm StopTech). Even if the diameter does not change, you should definitely check this to ensure that the brake functions properly. To do this, turn the brake disc on the wheel hub and check whether the brake disc touches the dust shield. It can also happen that the brake caliper collides with the dust shield; this can be checked later during assembly and, if necessary, rectified.

How do I install the Big Brake Kit?

It should be mentioned in advance that you should absolutely adhere to the tightening torques. The required tightening torques can be found in the respective installation instructions.
When assembling, we start by assembling the brake caliper bracket. The two screws are mounted from the inside out and then tightened.
Then we look for the right brake disc for the side we are currently working on and place it on the wheel hub. The brake disc can be secured with a wheel nut on the wheel hub for the assembly of the remaining components. At this point you can check again that the brake disc does not get in touch with any surrounding components.
Now we are looking for the right brake caliper for the respective side. These are marked with "L" or "R" on the pad retainer, the bleeder connection always belongs to the top when the caliper is mounted. We remove the pre-assembled pad retainer on this brake caliper so that the brake pads can be installed later. Now we can mount the brake caliper on the bracket and tighten it with the prescribed tightening torque.
Then we can insert the brake pads into the caliper (the back plate should face outwards in the direction of the brake caliper, not in the direction of the brake disc). Last but not least, the brake pads must be secured in the brake calliper with the pad retainer tightened according to the StopTech specifications.
Now we are reconnecting the new Big Brake Kit to the rest of the vehicle's braking system. It is best to attach the new steel braided hose to the brake calliper first, but do not tighten it yet. Then do the same on the connection between the steel braided line and the rigid brake line on the car. For the brake lines, it is extremely important to mount these without twisting, so be sure to pay attention to this. When you have the brake line in the car without twisting, you can tighten the connections to the brake caliper and brake line. Then move the steering to full lock on both sides and check that the brake line is not too tight on the pulled side and that it doesn't touch anywhere on the pushed side and that it can scratch later. A leak in this line means an extremely reduced braking effect and, in the worst case scenario, can result in an accident.

What else do I have to do before getting on the road with the car?

In any case, you should bleed the entire brake system in 2 passes. Then you can check the brake pressure, simply step on the brake pedal several times and see whether the system is holding the pressure. This has the pleasant side effect that the brake pads are already in contact with the disc and do not have to be "pumped up" first.
Then you can carefully attach the wheels and check directly whether your rim fits over the brake system or whether the rim is touching the brake system somewhere. If this test is successful, you can attach the wheels to the car. Before you can test drive the car, you should definitely check the brake pressure again. This is followed by a careful test drive in a safe environment, followed by a final leak test of all brake components.

Your new brake system is now perfectly prepared for its first use on the road or on a track day. Do you have any further questions? Just write a comment under this post or write us an email!

Your SPS Motorsport Team