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StopTech Rotor Replacement
 
StopTech 2-piece rotors use lightweight aluminum hats connected to iron rotors (also called "friction rings") by hardware which allows them to "float" and expand freely.  Thus, they are known as "floating rotors."
 

Rotor (friction ring) attached to aluminum hat

Although you can't see it in the photo, the hardware passes through oval slots in the rotor rather than circular holes.  Since iron and aluminum expand at different rates, the slots allow the hardware to slide and the rotor to expand and contract, unconstrained by the aluminum hat.  This system greatly reduces the stress on the rotors at high temperatures and extends their life.  Conventional 1-piece rotors tend to distort into a cone shape during race conditions, leading to tapered pad wear and stress cracks, especially at the outer edges.

Each StopTech rotor comes complete with an installation kit, consisting of 4mm Allen screws, Inconel (Nickel alloy) Belleville washers that act as anti-rattle springs, drive pins, Loctite 290 thread locking compound, and an instruction sheet.

4mm Screw

Inconel Bevel Washer

Drive Pin

Note: It is strongly suggested that you use new hardware whenever replacing rotors.  For this reason, all StopTech rotors are now sold with the mounting hardware INCLUDED in the sale price.

  1. Remove rotor and hat assemblies from vehicle.

  2. Remove the Allen bolts from the drive pins with a 4mm Allen wrench. To avoid stripping the bolts, be sure the end of Allen wrench is not rounded from excessive use.

The Loctite 290 applied at the factory is very strong, and occasionally a bolt may strip. Heat may be used to soften the Loctite. In extreme cases, it may be necessary to use a vise grip to grab the head of the bolt and break it loose.

  1. Remove old drive pins from hat and discard.

It may be necessary to tap out some pins. If a drive pin is really tight, screw one of the old bolts into the drive pin from the inside of the hat and tap the pin out by hitting the bolt head. Be careful not to drive the head of the bolt into the hole in the hat. A drop of light oil on the outside of the pin body may help.

  1. Lay new rotor face down with mounting flanges facing up.

  1. Place hat on top of rotor

  1. Install new drive pins into hat. They should slide in, but light tapping is not uncommon. Be sure flat on pin aligns with the hat as before.

  1. Flip rotor over and install bolts and bevel washers finger tight.  The concave surface faces downward, making the washers appear as small domes.

  1. After installing all bolts finger tight, lay the rotor, hat-side up, on a flat surface. Place a drop or two of 290 Loctite into the ends of each drive pin. This special Loctite is designed to wick into the threads and should NOT be applied to the bolts before installation.  Loctite must be applied BEFORE you tighten the bolts with the torque wrench.  Allow assembly to sit for a few minutes, while Loctite flows into the threads.

  1. Tighten the bolts to 72 in/lb (6 lb-ft).

  1. Rotors can immediately be installed on the vehicle and bedded in.

NEW ROTORS MUST BE BEDDED IN.

The proper break-in procedure is documented here: Bedding in new pads and rotors

If you have any questions about rotor installation or any brake related issues, please call Zeckhausen Racing before you start taking things apart.  If you prefer, hats may be mailed to Zeckhausen Racing and new rotors pre-installed for you for a nominal charge.

To order by phone or for technical assistance:

Call (800)222-8893 and press "1" for Sales

International customers may call: 973-761-5054

Hours of operation: Monday-Friday, 10AM - 5PM  (Eastern Time)

We are located in Fairfield, New Jersey

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Copyright © 2008 Zeckhausen Racing, LLC
Last modified: 09/15/08