I picked up a set of 406 axles with the pinion conversion already done.
I am planning on putting them under a 2001 tj. H1 rims with 42” pitbulls.
They do not have any brakes. This is where my problem comes in to play.
I am not sure where to start looking as where I can a part list of what I am going to need.
I have search but have not found any thing as of yet.
So that leads me to here and asking you.
What am I going to need to put disc brakes on these axles?

part numbers for all the stock components can be found in this pdf.

http://sceep.boogerwelds.com/sob/buggy/SEE_technical_manual_axles_only.pdf

contact expedition imports or any of the other vendors for OEM parts. (OEM parts will NOT work with h1 wheels AFAIK)

as for a custom solution.. no clue.

sent you a PM!!.... :D

part numbers for all the stock components can be found in this pdf.

http://sceep.boogerwelds.com/sob/buggy/SEE_technical_manual_axles_only.pdf

contact expedition imports or any of the other vendors for OEM parts. (OEM parts will NOT work with h1 wheels AFAIK)

as for a custom solution.. no clue.

Thank you.

Here is a pic of the stock rotor and hub

http://luxjo.supermotors.net/74%20ROCK%20CRAWLER/BRAKES/DCP03762.JPG

If your running H1's, you won't need the calipers or brackets. No way they will fit. The rotors will need to be cut down, and even then you are very limited on a caliper that will fit.

If you recenter the H1's and go with very little backspacing, that might help, but don't think it will leave you with even close to the correct geometry.

At first, I was going to keep the stock hubs and use a cutdown rotor.

http://luxjo.supermotors.net/74%20ROCK%20CRAWLER/HUMMER%20RIMS/DCP04233.JPG

I cut down a board to simulate a cut down rotor and tried to fit a small twin piston caliper, but I just could not make it work.

http://luxjo.supermotors.net/74%20ROCK%20CRAWLER/BRAKES/DCP03765.JPG

Here is the rotor, not cut down yet ,and you can see how little clearance there would have been with that caliper (if was from a late model explorer).

http://luxjo.supermotors.net/74%20ROCK%20CRAWLER/BRAKES/DCP03763.JPG

So I decided to use wildwood calipers, which would have fit, but many claimed they did not have enough clamping force for a heavier rig (I'll be over 5K, most likely).

I ended up getting another set of 406's, which the seller had made custom made alum 8 lug hubs, using GM rotors. Even with that, I still could only fit the wildwoods if I was sticking with the 16.5 rim.

http://luxjo.supermotors.net/74%20ROCK%20CRAWLER/406%20MOGS/BRAKES/DCP04686.JPG
http://luxjo.supermotors.net/74%20ROCK%20CRAWLER/406%20MOGS/BRAKES/DCP04688.JPG
http://luxjo.supermotors.net/74%20ROCK%20CRAWLER/406%20MOGS/BRAKES/DCP04687.jpg

I ended up getting 17" beadlocks and selling the H1's when the 43 SX stickies came out, but not sure yet what caliper might fit.

I know someone running 404 with the adapter and GM rotors and calipers. And he is running H1 rims.
Are the 404 that much smaller than 406?

Yes, the 404 portal is a fair amount smaller than the 406 portal.

I know someone running 404 with the adapter and GM rotors and calipers. And he is running H1 rims.
Are the 404 that much smaller than 406?

Yes, I am running 404's with GM single piston calipers and stock H1's now.
box vs box

http://luxjo.supermotors.net/74%20ROCK%20CRAWLER/406%20MOGS/404%20vs%20406/PORTAL%20BOXES/DCP02244.JPG

http://luxjo.supermotors.net/74%20ROCK%20CRAWLER/406%20MOGS/404%20vs%20406/PORTAL%20BOXES/DCP02245.JPG

When you see them that way you can really see the difference.
Why did you go with the 404?

404's are so cute!! :grinpimp:

When you see them that way you can really see the difference.
Why did you go with the 404?

It was over 8 years ago, mogs were just coming around. 404's just happened to be first.

They are not that bad. My rig is 6300 lbs and I only broke one ring and pinion all that time. I do get it sometimes, but always back off when it starts hopping.

404's are so cute!! :grinpimp:

HAHA!!, and I'd still take them over a 60 any day.............

404's are so cute!! :grinpimp:



:laughing:

oh, wait, I have 404's :(

That side-on pic actually makes it look like the 406 style box would fit a smaller rim easier. The interference point on the 404 is the two ears on the inner half of the box right at the top. The 406 looks to have a smaller, rounder profile at that point. Could just be that pic though?

http://luxjo.supermotors.net/74%20ROCK%20CRAWLER/406%20MOGS/404%20vs%20406/PORTAL%20BOXES/DCP02245.JPG

So are you saying that stock H1 rims will not fit on a 406 with disc brakes?

So are you saying that stock H1 rims will not fit on a 406 with disc brakes?

not with the factory discs.

not with the factory discs.

I was not planning on using the factory disc.

I am running wilwood dynalites with 49" michelin XLs on my 404 and they work great on a '78 chevy rotor.
Of course... I am using two per wheel in the front... and compound H pads.

ooh ooh and a hydroboost.

I am running wilwood dynalites with 49" michelin XLs on my 404 and they work great on a '78 chevy rotor.
Of course... I am using two per wheel in the front... and compound H pads.

ooh ooh and a hydroboost.

I had heard the wildwoods and HB were a nogo due to the higher pressure.
Which HB are you running?

90? ish astrovan.

I have the booster attached to a side by side 1&1/8 CNC brake corp master. Works really well.

90? ish astrovan.

I have the booster attached to a side by side 1&1/8 CNC brake corp master. Works really well.

Good to hear. I'm still on the fence as to wether I want one PS pump to run my front 3" ram and the brakes. My vac brakes work good now (using dual diaphr F350 booster), but the booster is huge and the new build has much smaller body.

Any idea what line pressures you are seeing?

Also good idea on the twin calipers up front, will keep that in the back pocket.

Good to hear. I'm still on the fence as to wether I want one PS pump to run my front 3" ram and the brakes. My vac brakes work good now (using dual diaphr F350 booster), but the booster is huge and the new build has much smaller body.

Any idea what line pressures you are seeing?

Also good idea on the twin calipers up front, will keep that in the back pocket.

If I had it to do again I would use two pumps or a smaller steering ram. I am using a 2" ram and it is just bigger than it needs to be, though it is nice to be able to push yourself sideways off of a lamp post on asphalt or to nudge dead scouts out of the way in my buddies yard when you need just a little more room to make that corner.

No idea on line pressure but no problems yet. If you are concerned about popping your calipers put in a relief to tank valve.

The dual calipers works well, Plus it looks 'bitchin!

I'm in the process of putting discs on 406 axles with H1 wheels. Using custom aluminum spacers, chevy rotor and 2003-2004 dodge dakota caliper. I know it fits in the wheel and the "calculated" brake force is more then my 404's with stock drums but real world testing will have to wait till it's done.

Cool. That is what I want to do.
Keep us posted on the out come.

I could only find one picture of the adapter so i'll take some more pics of the brake setup when i get a chance.

Ive read all of the major portal threads(JR's,Jason's,72Greg) as my new project is getting custom portals. As of now taking two 419 rear axles cutting the boxes off and fabricating an outer knuckle to connect to spider trax pro sieres inners and 9 inch housings:D


From all this I think Jason did it with the least effort, turned the stock rotor down and mounted an f350 caliper


http://pirate4x4.com/forum/showthread.php?t=594481&highlight=willywanter&page=7

He has recentered wheels from what i've read. The OP wants to use stock H1 wheels. i tried the F-350 calipers shown but the finned area and brake line hook up interfered with the wheel. The dakota caliper is almost the same piston size as the f-350 and was the largest i found to fit. Pistons are around a 1/4 inch bigger then the pathfinder.

I'm in the process of putting discs on 406 axles with H1 wheels. Using custom aluminum spacers, chevy rotor and 2003-2004 dodge dakota caliper. I know it fits in the wheel and the "calculated" brake force is more then my 404's with stock drums but real world testing will have to wait till it's done.


exactly what rotors and calipers ??

I'm using the 2005 chevy 2500 rear rotor (i believe i got the part number from you) and 2003-2004 Dodge dakota front caliper. I can get part numbers if you need them.
Also depending on how thick you make the aluminum adapter you could use a 2001 Dodge 3500 rear rotor (not sure what other years are the same) which is deeper so it would push your caliper inward possibly allowing the use of the F-350 caliper.