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[IrishCJ6]

Finally get the disc on the Jeep.The drums were never good, always had to be adjusted and always filled with crap after each run, oh and the handbrake sucked.

Cutting the old drum backing plate



Hub ready from brackets and disc



New disc dummied in place



New drop hose and tee piece installed



Part 1 of bracket build dummied in place



Bracket made





Caliper mounted on disc



New hoses and lines





Hand brake cables installed and joined to the old main cable



Brakes are bedded in and I now have a great pedal, a working handbrake (that holds on a hill) and a much cleaner unit to keep maintained.

 

[Lornaben]

 

Nice work 

[bigjeepzj]

nice job

[Delk]

What callipers did you use? I just ordered some newer Transit ones that I should get in the next day or two.

[UKJeeper]

Like that setup, a lot. Need a list of 'ingredients' though, not just the recipe. Thanks.

[Arno]

That looks brilliant. Would not mind getting the drums on my TJ swapped for discs !!

[IrishCJ6]

Ok, here is what I used, I will take a pattern of the bracket (when I take off the bracket to paint) but it is not just a flat plate that bolts on like the AMC 20 versions, the D44 (as I found out) has about a 12mm +/- offset outwards from the flange that requires you to offset the bracket (well on my setup using the same parts as the AMC 20 US versions did). What I did was made the first section that bolts to the flange, then made another to suit the caliper, I then mounted the caliper and caliper plate on the disc and used a inverted bridge weld to join the two together in the correct location. I also ditched the original hose pipes and hard lines as I wanted to convert everything to standard UK Imperial fittings hence the Landrover drop hose. You could just shorten the originals and use those if you want and just re-flare the ends but mine were original 35 year old parts and were toast. I also found that you need to dill the disc stud holes out from 1/2" to 16mm to clear the base of the stud. I also had to modify the handbrake cable attachment points to the caliper as they fouled the axle, I ended up cutting off the bracket and welding it to the axle tube in the correct position. I also had to change the bridge piece (Nissan Maxima piece) that joins the 2 cables to the main cable as the Jeep one did not suit, nothing major just a quick chop and weld. It took me the best part of 2 days to complete but I think it is worth it.

Jeep CJ Dana 44 Rear Disc Brake Conversion

Parts list:

1)   Suzuki Vitara (89 – 91) 1.6l 3 door front disc rotors (290mm x 10mm)
2)   Nissan Maxima A32 (95 – 00) 3.0 V6 rear brake callipers, handbrake cables and bridge piece
3)   Nissan Maxima A32 (95 – 00) 3.0 V6 rear brake pads
4)   Range Rover (70 – 80) rear brake hose (part No. GBH129)
5)   Toyota Corolla E11 (97 – 07) rear brake hose (x2)
6)   3/8 UNF Tee piece
7)   10mm copper washers (x5)
8.)   Brake pipe (Copper)
9)   2 x M10x1 male brake unions
10)   3 x 3/8 UNF male brake unions
11)   8mm Steel plate for brackets
12)   3/8 UNF longer axle retainer bolts and lock nuts

I think this is all the parts I used, keep all the bolts, clips and parts that came off the Nissan as I used most of these in the build. I'm willing to give more info to anyone that is thinking of doing this change. You will need to have a plasma cutter or access to oxy and be a proficient welder but other than that its pretty simple. When I take the bracket off to paint I will trace both the caliper plate and the flange plates and either upload to CAD or PDF them. If someone wants these they can email me for copies. You will need to weld them together though.

[Arno]

Wow - this is a very impressive parts list and build guide ... Well done!

You should consider selling this as a kit

I'm looking at doing this to my TJ at some stage, like you say, constantly have to readjust the brakes, and the handbrake is well, bleddy pointless..

I'm up for more info on this build, as from what I've seen over here in the UK, is kits are damn expensive and it's not easy to find something decent. 

I don't have access to a plasma cutter, but sure I can find an engineering shop / decent mechanic to be happy to help out!

[wildwood]

Don't laugh....... But if you haven't got a plasma cutter then. Marking  out with. The sharpie pen then cutting with the 1mm slitting disc and cleaning up with the belt sander will do the trick....
Works for me......l so far......

[Bulldog67]

Fantastic write up & list 

You have just added another job to two of my trucks so will def be in touch for all the gumpf (so I can show it to someone who knows what they are doing  )

[IrishCJ6]

Don't laugh....... But if you haven't got a plasma cutter then. Marking  out with. The sharpie pen then cutting with the 1mm slitting disc and cleaning up with the belt sander will do the trick....
Works for me......l so far......

1mm cutting discs are great but trying to cut curved shapes in 8mm might be difficult. Not saying it can't be done though. Even with the plasma cutter I still had to clean up the edges as I was cutting free hand and it wasn't that clean.

[chrisjones]

If enough people were interested it may be well worth getting together and paying to have some laser cut.  If you can get a reasonable quantity done the price should be reasonable.