I have looked around for an effective up-grade path for my 98 ZJ brakes and I have run across a few mentions of a WJ front brake swap. This sounds easy enough, however there is a lot of contradiction in the information I’m reading. Most of the data I find is more relevant to XJ's looking for a brake up-grade, or ZJ guys looking for better brakes and steering. I’m not looking for any steering up-grades, brakes only. My specific questions are as follows:

EXACTLY what WJ parts will I need to swap WJ front brakes onto my ZJ?

The ZJ is a 5x4.5 while the WJ is 5x5, So how is this issue solved? Do I run different lug pattern wheels front to rear, or do I need special rotors?

I plan on using a Dakota MC (pn# TS 102967 1 1/8 bore) after the swap, does this sound like a good idea?


The OEM ZJ brakes are complete shit and I’m going from a 245-75-16 to 285-75-16, so that’s only going to make things worse. I did a big brake swap and a 1 1/8 GM MC on my 87 Yota, and that bitch will put your teeth in the dash with 32's.

EXACTLY what WJ parts will I need to swap WJ front brakes onto my ZJ?

The ZJ is a 5x4.5 while the WJ is 5x5, So how is this issue solved? Do I run different lug pattern wheels front to rear, or do I need special rotors?

I plan on using a Dakota MC (pn# TS 102967 1 1/8 bore) after the swap, does this sound like a good idea?

Parts:

New brake rotors (use 2001 Sport Trac rotors)
New calipers and obviously pads
1/4" spacers to weld between the knuckle and the unit bearing (JKS makes them specifically for this swap)
New steering setup with new WJ tie rod ends because the WJs use a larger end than the ZJ, and the WJ's don't use a "Y" style steering setup like the stock ZJ does.


It's also probably a good idea to throw in some new ball joints while you've got the knuckle off anyway, but that's not a necessity or anything.

Parts:

New brake rotors (use 2001 Sport Trac rotors)
New calipers and obviously pads
1/4" spacers to weld between the knuckle and the unit bearing (JKS makes them specifically for this swap)
New steering setup with new WJ tie rod ends because the WJs use a larger end than the ZJ, and the WJ's don't use a "Y" style steering setup like the stock ZJ does.


It's also probably a good idea to throw in some new ball joints while you've got the knuckle off anyway, but that's not a necessity or anything.

Just so I’m crystal clear before I start buying parts, your telling me to use:

WJ calipers and pads.
WJ knuckles.
2001 Sport Trac rotors.
1/4" knuckle spacers.
WJ D/S and P/S tie rods and ends linking all the way to the pitman arm.


Aside from verifying my parts list (above), are there any issues with the WJ tie rods linking to the ZJ pitman arm or the ZJ steering damper???

I’m not sure if there is a difference in the OEM track width from the ZJ to WJ? If there is can this be compensated by simply adjusting in/out the swapped in WJ tie rod/steering assembly???

I just found an 02 front axle (WJ) complete with steering and knuckles, minus the brakes and piman arm, for $50. The guy said its from an 02 with an inline 6 (WTF?), I thought the inline went away in 99? Should I pick this up, what do you think?

I really appreciate the assistance and I’m looking forward to getting this done right the first time with your help, thank you.

These are instructions for a YJ but should basically be the same for your ZJ.

http://www.jcroffroad.com/WJ.html

And the 4.0 was used all the way through 04 in the WJs.

Just so I’m crystal clear before I start buying parts, your telling me to use:

WJ calipers and pads.
WJ knuckles.
2001 Sport Trac rotors.
1/4" knuckle spacers.
WJ D/S and P/S tie rods and ends linking all the way to the pitman arm.


Aside from verifying my parts list (above), are there any issues with the WJ tie rods linking to the ZJ pitman arm or the ZJ steering damper???

I’m not sure if there is a difference in the OEM track width from the ZJ to WJ? If there is can this be compensated by simply adjusting in/out the swapped in WJ tie rod/steering assembly???

I just found an 02 front axle (WJ) complete with steering and knuckles, minus the brakes and piman arm, for $50. The guy said its from an 02 with an inline 6 (WTF?), I thought the inline went away in 99? Should I pick this up, what do you think?

I really appreciate the assistance and I’m looking forward to getting this done right the first time with your help, thank you.


Yes on the parts list. Yeah the WJ tie rod will bolt right up to your pittman arm just fine. Also I did forget to mention that you have to build/buy a shortened trackbar. They also sell an over the knuckle mount for the trackbar which is what I'm using, but I think you can use it in the stock location as well. As for the steering stabilizer, you'll have to buy or build a bracket to mount that to your drag link. As for buying that WJ axle, it's a good buy, if only for the knuckles. I wouldn't swap the whole thing into my rig personally, just steal the knuckles and brakes off of it.

JKS offers some parts to do this swap under the FAB parts section on their site.