KORE3 Industries LLC

30569 Hwy 34 SW Phone: 541.924.5673

www.kore3.com Albany, OR 97321 i nf o@ kore3. com

KORE3 BIG-BRAKE CONVERSION

KIT FOR 1998-2005 RWD BLAZER APPLICATIONS

General: This KORE3 big-brake kit was designed to adapt C5(Z06) or C6(Z51/Z06/GS/ZR1) Corvette brake
components to the applications noted below, supplied with the unitized hubs and 2-piston calipers from
the factory. Please note that the smallest of these kits requires Ø17” or larger wheels for rotor/caliper
clearance. Please verify fitment of aftermarket wheels using our fitment templates available from our
website, www.kore3.com, or actual components.

 1998-2005 Chevy Blazer, RWD

 1998-2004 Chevy S10 Pickup, RWD
 1998-2002 GMC Jimmy, RWD
 1998-2004 GMC Sonoma, RWD
 1998-2000 Isuzu Hombre, RWD
 1998-2001 Olds Bravada, RWD
 Belltech #2102 2” drop spindle

Thank you for giving KORE3 the opportunity to work with you in the endless pursuit of automotive
excellence and we hope that you’ll do business with us again in the future. Please contact us via email at
info@kore3.com or call us toll-free at 800.357.5467 with any questions or feedback you might have.

I. KORE3 C5/C6 Big-Brake Installation:

Caution: A certified mechanic and/or person experienced in the installation, service and proper operation of disc
brake systems should perform installation of this kit. Please refer to the included TERMS OF USE,
WARRANTY & LIABILITY WAIVER included with this kit for important disclosures. Read and understand
all instructions prior to beginning installation. These instructions are intended to give general guidelines
to perform the KORE3 98-05 RWD Blazer big-brake conversion. Please refer to your vehicles factory
service manual for additional details as needed.

1. Chock the rear wheels and apply the parking brake (or put the transmission in gear or in park),
loosen the front lug nuts, jack up the front of the vehicle and support it with jack/frame stands.

2. Remove the lug nuts and wheels.

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 3. Remove the calipers, brake pads, and abutments, disconnecting the flexible brake line at the hard
line with the proper line wrenches to avoid rounding the tube nut.

4. Remove the rotors.

5. Disconnect the ABS sensor if applicable and remove the unitized-bearing hubs by removing the
three (3) M12-1.75 hex head cap screws from the back of each spindle. Remove the factory dust
shields, replace with supplied shim and reinstall hub per factory torque specifications.

6. Loosely install the 10440-01/2 caliper adapter brackets and mark the location of the lower caliper
mounting fastener head. Remove the bracket and clearance the knuckle for the head of the lower
caliper mounting fastener. Reinstall the bracket with (1) .048” shim between the bracket and
knuckle, then verify pad abutment bracket (PAB) to rotor alignment. The PAB’s should be centered
over the rotor +/-.02” [+/-.5mm]. Shim as required.

Note: If using the C6 Z06 or ZR1 calipers, use the caliper bodies for alignment purposes instead of the PAB’s
used with the floating caliper kits.

7. Clean the rotors. All grease, oils, and/or rust inhibitors need to be fully removed. Bare rotors
should rust almost immediately. Removal of certain rust inhibitors may require solvent; however the
final cleaning should be with soap and warm water for the best results. Dishwasher and/or laundry
detergent both work well. Zinc washed rotors should not rust when new, but should still be cleaned
using the same procedure.

8. Install rotors and use two lug nuts on each rotor to temporarily hold the rotors in place while
installing and assembling the caliper assemblies.

9. Mount the caliper abutments to the KORE3 conversion brackets using the supplied M14-2 x 35mm
SHCS fasteners and apply two (2) drops of threadlocker to each fastener. Torque to 125 ft-lb [170
Nm]. For C6 Z06/ZR1 brake installations, install the pads into the calipers and skip steps 10-13.

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Note: Loctite 242/271, medium/high-strength threadlocker (or any equivalent product), is suitable for this
application and behaves as a thread lubricant when you torque the fasteners to the proper specifications.
Generally hand tools and heat are recommended for disassembly when high strength threadlocker is
used.

10. Install the caliper pins, pin boots, pad abutment shims, and disc brake pads in the abutments.
Liberally coat entire surface of the pins and inside the pin boots with high-temp grease.

Caution: Remove any excess amounts of grease as it can contaminate the friction surfaces and ultimately
require pad replacement.

11. Install anti-rattle (preload) spring clips in calipers where applicable.

Note: C6(Z51) front calipers do not use anti-rattle springs.

12. Align the caliper mounting holes with the caliper pins in the abutment and attach using the hex head
caliper mounting bolts, (2) M8-1.25 x 20mm HHCS Class 10.9, typically supplied with the calipers.
Torque caliper mounting bolts to 25 ft-lb [34 Nm].

13. Make sure that the rubber caliper pin dust boots are securely seated in the grooves on the abutment
and caliper pins, as this will help ensure smooth operation and maximize component performance
and life.

14. Install new flex lines leading from hard lines to calipers and reconnect to calipers using new crush
washers at the banjo fitting; torque to 14 ft-lb [19 Nm].

Caution: Never reuse crush washers as they are designed for one-time use only.

15. Connect to hard line and torque to 17 ft-lb [23 Nm] using the appropriate line wrenches.

Caution: Do not use Teflon tape or other thread sealer/lockers on flare type brake line fittings, as it can
actually prevent the fittings from properly seating and cause an unsafe condition.

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Note: Both rubber and braided stainless Teflon hoses can yield satisfactory performance, however the braided
stainless lines will give you a firmer pedal due to less expansion under pressure and can have a much
longer service life when properly installed and maintained. KORE3 recommends the use of DOT
compliant (FMVSS106) brake lines/hoses for all applications, regardless of hose material preference.
KORE3 offers FlexKORE brake lines for any and all custom applications.

16. Make sure that the brake lines are long enough and don’t interfere with any moving parts. Turn the
tires lock to lock and cycle the suspension to verify flexible brake line routing. Failure to properly
ensure that your brake hoses are routed safely and securely now may lead to sudden brake loss
later.

17. Bleed the brakes thoroughly. If you haven’t completely flushed your brake fluid within the past 2
years, now would be a good time. Most vehicles are rated for DOT3/4 brake fluid, which typically
performs well with regular fluid change intervals. Only use brake fluid from a previously unopened
container and try to avoid buying large containers of brake fluid that could go unused for long
periods of time for best results.

Caution: If your system currently has DOT5 type silicone based fluid, do not compound the problem and
change back to DOT3/4/5.1 glycol type unless you intend to change every component in your brake
system. The two fluid types are not compatible and it is all but impossible to completely flush out silicone
brake fluid. KORE3 does not recommend the use of DOT5 type silicone based brake fluids for
performance applications.

18. Install wheels and lug nuts.

19. Verify fitment and clearances. Completely inspect all of the components making sure that nothing
interferes with any moving parts. Adjust steering stops if necessary. If you, the installer, have
any questions, please get them answered before driving the vehicle.

Note: Final fitment of the wheel to the caliper is the responsibility of the customer. Verify that there are no
interferences between the wheel and the caliper, both radially outward and between the spokes and the
face of the caliper. Pay special attention to the valve stem and lead balancing weights and relocate them
as necessary, keeping in mind that if you rotate your tires, this will need to be checked on all of your
wheels, including your spare. Wheel spacers are not recommended by the Wheel Industry Council, and
may or may not meet certain legal requirements. It is the sole responsibility of the customer to properly
specify and install wheel spacers if they are to be used. Please contact us if you have any questions
regarding your installation.

20. Remove the vehicle from the jack stands.

21. Torque the lug nuts in a crisscross pattern in 25 ft-lb [34 Nm] increments up to final torque of 85 ft-
lb [116 Nm] for M12x1.5 studs. Studs should have at least 8 turns minimum thread engagement on
each lug nut.

22. Test the brakes in a safe, off-road environment. Don’t assume anything. The pads and rotors
should be bedded-in for best performance and life as per the rotor and/or pad manufacturers’
recommendations. This typically consists of heat cycling the brakes a few times by consecutively
more aggressive stops followed by cool down periods.

23. Torque the wheel lug nuts again after driving the vehicle 25-50 miles [40-80 km]. Retorque wheels
every 100 miles [161 km] until the torque is maintained and then follow standard maintenance
intervals. Inspect all brake components at this time as well for any interference, leaks, or other
such problems.

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II. Exploded View & Part List:

Please refer to the following exploded view and parts list in conjunction with the instructions. Parts shown and
listed below are for your reference only. Some of the items are optional and may or may not have been included
in your kit. Please refer to your original invoice and/or packing list for details regarding what was included with
your purchase.

[INSERT EXPLODED VIEW HERE]

KORE3 98-05 RWD Big-Brake Kit: C5/C6 Ø325mm [12.8”]

Item KORE3 # Qty Description Reference #
10018-01 Rotor, 325 x 32, 5 x 4.75, 70.5, LH, Plain GM #19175116
1 ea
10171-01 Rotor, 325 x 32, 5 x 4.75, 70.5, LH, D&S N/A
1
10019-01 Rotor, 325 x 32, 5 x 4.75, 70.5, RH, Plain GM #19175115
1 ea
10172-01 Rotor, 325 x 32, 5 x 4.75, 70.5, RH, D&S N/A
2 10440-01 2 ea KORE3 Big-Brake Bracket, 98-05 RWD Blazer N/A
3 N/A 4 ea M14x2 x 45mm HHCS, 10.9 N/A
4 N/A 4 ea M14x2 Flanged Locknuts N/A
N/A 8 ea M14 Flat Washers N/A
5 N/A 4 ea M14x2 x 35mm SHCS, 12.9 N/A
6 N/A 4 ea M8-1.25 x 20mm HHCS, 10.9 GM #14067559
10210-01 Caliper, Front Left, C6 (Black Anodized) GM #19208033
1 ea
10029-02 Caliper, Front Left, C5, Z06 (Red) GM #88895128
7
10030-01 Caliper, Front Right, C5 (Black Anodized) GM #19208034
1 ea
10030-02 Caliper, Front Right, C5, Z06 (Red) GM #88895129
8 10035-02 4 ea Caliper Pin, C5/C6 GM #12530697
9 10037-02 4 ea Caliper Pin Boot, C5/C6 GM #12530703
10 10214-02 2 ea Pad Abutment Bracket, Front, C5/C6 GM #88955518
10017-02 Brake Pad, C5/C6, Front, ACD Ceramic GM #88909667
11 1 ea
10017-03 Brake Pad, C5/C6, Front, ACD Semi-Metallic GM #18038570
12 10543-048 2 ea Shim, Hub, 98-05 RWD Blazer N/A
13 N/A 8 ea Shim, 9/16, .048” N/A

Substitute the following items when running the 340mm x 32mm C6 Z51 GMF4 big-brake kit.

KORE3 GMF4 Big-Brake Kit: 340mm [13.4”]

Item KORE3 # Qty Description Reference #
***Following rotors used with KORE3 Billet Hub Kit: 5 x 4.75, 70.5***
1 10101-01 2 ea Rotor, 340 x 32, 5x4.75, 70.5, Drilled, C6 Z51 GM #89060328
10 10099-02 2 ea Pad Abutment Bracket, Front, C6 Z51 GM #88964166

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Substitute the following items when running the 355mm x 32mm C6 Z06 GMF4 big-brake kit.

KORE3 GMF4 Big-Brake Kit: 355mm [14.0”]

Item KORE3 # Qty Description Reference #
***Following rotors used with KORE3 Billet Hub Kit: 5 x 4.75, 70.5***
1 10156-01 2 ea Rotor, 355 x 32, 5x4.75, 70.5, Drilled, C6 Z06 GM #19121787
10152-01 Caliper, 6-Piston, Left Front, C6 Z06 GM #19121788
7-10 1 ea
10153-01 Caliper, 6-Piston, Right Front, C6 Z06 GM #19121789
11 10158-02 1 set Brake Pad Kit, Front, C6 Z06 GM #19169648
Substitute the following items when running the 355mm x 32mm Hybrid GMF4 big-brake kit.

KORE3 GMF4 Big-Brake Kit: 355mm [14.0”] Hybrid

Item KORE3 # Qty Description Reference #
***Following rotors used with KORE3 Billet Hub Kit: 5 x 4.75, 70.5***
1 10156-01 2 ea Rotor, 355 x 32, 5x4.75, 70.5, Drilled, C6 Z06 GM #19121787
2 10440-02 2 ea KORE3 Big-Brake Bracket, 98-05 RWD Blazer, Hybrid N/A

Teflon is a registered trademark of DuPont.

Corvette, C5, Z51, Z06 & ZR1 are registered trademarks of the General Motors Corporation.

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