DIY - Gen II Stoptech Big Brake Kit Install 1999 GTS ACR Non-ABS Front and Rear
So far fairly straight forward. Support car with jack stands. Remove wheels. 18mm socket to loosen top caliper bolt. Remove 18mm lower caliper bolt. Leave top 18mm bolt installed. Remove 15mm brake line bracket and tie up caliper. It rests with slack on floor so that step could be optional. Re-install 15mm brake line bracket bolt. I used some anti-seize to be safe.
Calipers came off with only minor wiggling. Rotors came right off by hand.
Next step is to clean/detail before carrying on to the next steps.
Spent some more time on it tonight. Used Simple Green and Brake and Parts Cleaner to clean up around the control arms and hub area.
Removed brake line and caliper with a 3/8" open end wrench. A pre-soak with penetrating fluid might have helped a little but I powered through without stripping them. A 13mm was used to remove the brake line mounting bracket. The 13mm was reused for the new brake line bracket.
Attaching the new caliper bracket was easy with a 10mm hex. Use the supplied Loctite.
Finished the front big brake kit install tonight. Still have to bleed the brakes. I will bleed them after the rear kit is installed. Was extremely easy with basic tools. Spent more time taking pictures than installing.
Cutting the ears/tabs was less dramatic than I thought it would be. Used a corded reciprocating saw. I didn't even put a new blade in. Used the one that was in it from before. Went smooth. I hand sanded the burrs off with 120 grit. I will grab a sander from work and remove the marks from the saw to clean up the edge nice. Overkill but if I don't it will probably bug me. I found that the saw was offset to one side so the blade has more clearance when cutting on the one side. Going to the opposite side I just cut upwards instead to give me the same clearance around the hub/lug nuts while cutting.
More progress tonight. Used a 3" air powered grinder with 36 grit to shave down the lower arm for clearance. Installed rear caliper bracket and park brake bracket. Rotate axle shaft slightly for better access to each 3/4" bolt as needed. Should have the rest completed in the next day or two.
Back brakes are done minus the parking brakes. The parking brake relocates the stock calipers. They don't look as good as the new Stoptech calipers so I will take them to work, clean them up and refinish them to match. After that I will power bleed them with a MiteyVac. Full brake flush and fill with new fluid.
Wrapped up the rear. Attached the parking brake assembly which is the old caliper switched from right to left and left to right. Cleaned up the old caliper and refinished it black. Pads were too thick and needed to be ground down. Wear a mask and do it outside if possible. Very dusty and it stinks. Everything else was straight forward. The Stoptech instructions were very helpful. The only fault would be the quality of images they use. They might be good in a pdf file but not when printed.
Just need to bleed. I'll pick up some brake fluid in the next day or two.
]Finished up with the bleeding/flushing of the brakes and master cylinder. Cleaned out the clutch master cylinder as well. Glad I purchased the MiteyVac. Grabbed it from my Snap-On dealer. Simple to use and very effective.
Siphoned the old fluid out and then attached the vacuum end to the bleeders. Kept the master cylinder topped up. The kit cam with an auto fill but it didn't want to balance on the master cylinder so I just kept it topped up.
Was going good until I got to the front right caliper and found that it wasn't bleeding as if it had a blockage. Found the outer bleeder with some corrosion. Replaced it with an original bleeder and just pumped the brake pedal to clear whatever the blockage was. Bled fine after that.
Used about 1500ml total of DOT4 Mopar brake fluid.
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