Rear disc brakes in progress

[EricsXJ]

Just an update -

I'm in the middle of installing my TeraFlex rear disc brake kit on 8.25 rear axle. Its basically the same process as a lot of guys do with ZJ parts only this kit uses Explorer brakes I believe (I will confirm this with TeraFlex). The kit is sweet and also works with the D44 and Dana turdy5. They use a different version of the same kit for 8.8 and Ford 9".

I got a slow start as I ran into a problem removing my c-clip shafts. I went to remove the retaining pin to get the cross shaft out when I noticed the head of the pin is cracked all around it. ARB uses a recessed pin that takes an allen key to remove it. I remember a guy on NAXJA that broke the retaining pin and had serious problems getting the cross shaft out. So I was worried. I called ARB and they are sending me a couple pins and gave me some advice on getting that thing out. It was tighter than it should be to remove, which was what worried me because I didn't want to break the head of that pin off... I heated the case up a little with a torch and got the pin unscrewed. Thank goodness it didn't break on me.

So I've got the brakes about 3/4 the way finished - also replacing the stock shafts with Yukon alloys :D and I've got a few days to finish it (working slow - taking pictures of course) before the pins arrive to finish it up.

Should be done by Bronco Canyon!

[xjmoser]

Those stock rear brakes suck!


I was thinkin about the zj route when I can afford to do mine. Let me know how much of a difference it makes.

[EricsXJ]

They say it makes so much difference that you don't need to change or modify the proportioning valve or master cylinder at all, even though I have read posts about people modifying the prop valve when doing the ZJ swap. I will let you know how it turns out!

[Denis]

i've heard form a reliable source that the prop valve used in TJs with drum brakes is exactly the same as the one in disc brake equipped TJs. i know people pull the o-ring out of the prop. valve, but it doesn't sound like it's neccessary.

on the other hand, upgrading to a ZJ master cylinder was recommender to me as something that i need to do, when going with disc brakes.

[EricsXJ]

Well I finished the project late Thursday night and test drove it today. There is a noticeable difference in stopping power. I was expecting a little firmer peddle but the fact is, the jeep stops sooner and with less peddle pressure than before. I'm pretty sure I could lock up the brakes on the street but I haven't tested that out yet. Last thing I need to do is connect the e-brake - it seems like all the write-ups I have looked at all have this problem - it would have been nice if TeraFlex would include a simple connector or something but they don't.

[kairo]

How much was the kit if you don't mind me asking? and did you order it from Teraflex?

[EricsXJ]

How much was the kit if you don't mind me asking? and did you order it from Teraflex?
No not from TF - it probably would have been too much. Last I checked TF don't have any prices listed on thier site but I checked www.mepco4x4.com which is closely related to TF in some way and they have the kit listed at some pretty unrealistic prices. They show regular price $549.95! And sale price of $479. I bought mine from www.dc4wd.com for less than that shipped. I think with shipping it was $465 or close to. I'm kind of kicking myself though because I have heard some people getting the kit at a lower price than that. I think I saw a thread on JF in the vendor section where DC4wd was selling it even cheaper. It might pay to look around.

Also, after reading some of the articles online about people who used ZJ parts, most of them still paid a decent amount of money for the parts - a couple hundred bucks unless you pull all used stuff at the junkyard, but I would imagine you would still want new rotors and pads, maybe new calipers. On one online article which is no longer available, the guy ended up paying more than $500 in ZJ parts, so in some cases buying the TF kit may be the better deal.

[blackwidow]

so is there any pics of the build up. I'd be interested in it, want to do that as well

[EricsXJ]

Not yet, but heres one of the writeups for ZJ brakes swapped to a 8.25. http://home.swbell.net/rriojas3/reardisk.html Doing a D44 is a little different because you don't need to open the diff (no c-clips) but you do need to use a preload spacer or something near the backing plate. Here is an article for the swap on the D44 http://www.madxj.com/MADXJ/technical/technicalfiles/BAzjRearDiscsOnXJ/ZJrearDiscsOnXJ.htm if you want to do this let me know and I'll give you the spacers that came with my TeraFlex kit.

[Denis]

or you can use these (on the left). they are newer Jeep TJ retainer plates for disc brake equipped TJs. about $5 from the dealer for 2.

http://www.stu-offroad.com/suspension/d44brake/bc-02a.jpg

[xjmoser]

I should be getting a 98 zj rear d44 axle with disks brakes later this week.

[blackwidow]

that's gonna be sick Tom, can't wait to see it

[xjmoser]

Im just doing the disk swap onto my 8.25 :D




does anyone know what years had the aluminum center section on the zj 44 or is it all?

[blackwidow]

i want to do that on my d44 some day soon too!

[EricsXJ]

Im just doing the disk swap onto my 8.25 :D


You had me worried there for a moment! I'd take a 8.25 over the ZJ D44 any day. I don't know what years had the aluminum diff...

[xjmoser]

axle showed up today, all the parts are there :D Now to order new brakes and have the rotors turned.


Hopefully if all goes as planned they will be installed sunday.

[whiteZJ]

Tom- if your still wondering the ZJ 93-95 all had the awsome D35c no matter what engine. The 96-98 ZJ had al D44 w/ the V8's, and the D35c's came on with the I-6. good to hear your takeing only the brakes and not the whole axle. the al D44 suck :yup:

[xjmoser]

DONE!


I now have rear disk brakes :yup:

I did them today after work and it tool about 3.5hrs including clean-up. I cant believe how smooth it went. Just like the write-up and of course I forgot my camera at home.


I did notice a little better brakeing at low speeds but I really noticed it when I was getting off 395 at panther and almost locked it up :eek:

I would definatly do it again well worth the time and money ($50.00)

[EricsXJ]

Good job! :thumbsup:

[Sauce]

Good job! :thumbsup:
dang, you work fast tom, I think it took eric like 10 weeks to do his :rolleyes: :yup:

[EricsXJ]

dang, you work fast tom, I think it took eric like 10 weeks to do his :rolleyes: :yup:

I know... :rolleyes: I just finally got around to hooking up the e-brake cables a couple days ago!

[xjmoser]

Here are a couple pics of the new disk setup.

[Scrub]

WoW looks good, just one more thing to add to my list of stuff to do when i get money.

-Matt-