: Need some help with a TSM rear disc brake conversion


Blitzkrieg
04-19-2003, 02:07 PM
I am putting this kit on my TJ D44, with rear E-brake calipers. I have the base bracket installed and rotated to its highest position. I needed to do this in order for the caliper to clear my rear shocks. I then installed the 2 5\16" spacers and the 1\8" sapcer. These are both needed to space out the caliper bracket enough to get it past the T bolts that hold the axle flange, spacer and base bracket on. Then I installed the rotor on the end of the axle. Here is where my problem is. When I tried to install the caliper, with the outboard side pad, I couldn't get it to clear the mounts on the bracket. The treaded sleeves that they have welded to the mounts stick out a 1\4" to far towards the inboard side. So the outboard side pad hits the rotor before I can get the caliper on the mount. I can take out the pad and install the caliper but then I can't get that outboard pad back in.

From what I can see I have 2 options. Both options mean that I need to modify the bracket. I can notch out the bracket so that it fits around theT bolt and I only need to use the 2 5\16" spacers. The problem with that is I'm sure that will not get me the 1\4" needed to get passed the mounts since I will be able to only take out the 1\8" spacer. THe other thing I can do is cut down the threaded sleeve so the calipers have enough room to slide over. I was thinking that I would have to do the both of these. I can't call TSM, they are only open M-F.

Thanks for any help.

onsafari
04-19-2003, 03:32 PM
I think I know what your problem is. The slides (part that bolt goes through) slide back and forth allowing the caliper to float. If you slide them to the inboard of the Jeep the caliper will slide right over the rotor.

Give that a shot

Blitzkrieg
04-19-2003, 05:14 PM
Its not the slides that are the problem; its the cast mounting ears of the caliper. They won't pass over the threaded sleeves.

odee
04-20-2003, 10:33 AM
might try swaping mounts from side to side.

Blitzkrieg
04-20-2003, 10:48 AM
Tried that. It looks like the brackets are exactly the same. Eitther way the mounting sleeves are suppose to be on the inside. We took some digitals and are sending them to TSM. I will be calling them in the morning.
Thanks

Blitzkrieg
04-21-2003, 06:42 PM
Talked to Skip today at TSM. He suggested that I cut the treahded sleeves and try it. So thats what we did. He wants me to let him know how it worked out since no one else had the same problem.

I just must be lucky.