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Old 05-10-2006, 12:21 AM   #1 (permalink)
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junkyard 9 " disc brake conversion

anyone got any good tips or a parts list for a junkyard disc brake swap for a ford 9 inch from a 78 bronco? trying to spend as little money as possible. looking to use a caliper that has the ebrake built into it.
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Old 05-10-2006, 01:28 AM   #2 (permalink)
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Old 05-10-2006, 06:44 AM   #3 (permalink)
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I used Suzuki Sidekick rotors, Subaru front calipers and made my own brackets.

The 93 Subaru Loyale front calipers have a mechanical lever for e-brake and the Suzuki rotors have the same bolt pattern as the Ford axle and fit the Subaru calipers. When everything is all together, the bracket is just a flat piece of plate and no shimming or welding is required.

A few pics:












Super easy to make. The brackets are only held on by the flange bolts in the pics but they will be welded to the axlehousing for maximum strength. As for the e-brake setup, take a look at a Toyota truck setup and that is what I'm going to fab up to work with the calipers.


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Old 05-10-2006, 11:49 AM   #4 (permalink)
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did you use 1/4 or 3/8 thick steel for your brackets?
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Old 05-10-2006, 12:04 PM   #5 (permalink)
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Quote:
Originally Posted by bigerikt
did you use 1/4 or 3/8 thick steel for your brackets?
I originaly wanted to make them from 3/8 but I had some 1/4" lying around so I made them from that. Because the bracket is not offset or shimmed in any way, I think it will be plenty strong. Keep in mind that this axle is going under a LWB Samurai on 35" Boggers. If It was going under a FSB with 40"+ tires I might have found some 3/8" steel plate to make them from instead.


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Old 05-10-2006, 01:41 PM   #6 (permalink)
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I know you can swap the rear brakes off of a 90's crown vic on to a small bearing 9" rearend (I did it on my 67 mercury cougar), but not sure if it works on the big bearing rearend. Everything is a direct bolt on replatment except for parking brake cables. I did it for under 100 bucks.

I have heard about exporer rear disks off of 8.8's working too.
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Old 05-10-2006, 04:45 PM   #7 (permalink)
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if i'm not mistaken, the explorer disk brakes are 5 on 4.5, not 5 on 5.5 that 9's are. so that conversion would require different rotors or redrilling the 8.8 rotors? please correct me if i'm wrong.

and the lincoln versailles had disks and a 9" but it was a small bearing i think.
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Old 05-10-2006, 05:08 PM   #8 (permalink)
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the 8.8 explorer disks are a common swap, and great if you want to change bolt pattern, if not then you would need redrilled rotors.

Almost all 9" aftermarket kits use explorer disks
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Old 05-10-2006, 05:16 PM   #9 (permalink)
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cool. i had no idea, always good to learn something new.
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Old 05-11-2006, 01:29 PM   #10 (permalink)
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check my thread. next few days my super duper cheap 9 inch conversion is going to be installed.

search under the newbie jeep forum for a disc brake conversion i did on a dana 35.... besides the tech in there, im using all the same hardware, and the funnay at the end of the thread
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Old 05-11-2006, 02:54 PM   #11 (permalink)
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Originally Posted by 352Ford
I know you can swap the rear brakes off of a 90's crown vic on to a small bearing 9" rearend (I did it on my 67 mercury cougar), but not sure if it works on the big bearing rearend. Everything is a direct bolt on replatment except for parking brake cables. I did it for under 100 bucks.
I'll try that. My 9" came off a 68 Cougar and is 5 on 4.5. Is the Crown Vic 5 on 4.5 or 5 on 5.5?
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Old 05-11-2006, 04:32 PM   #12 (permalink)
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Quote:
Originally Posted by bigerikt
I'll try that. My 9" came off a 68 Cougar and is 5 on 4.5. Is the Crown Vic 5 on 4.5 or 5 on 5.5?
5 on 4.5


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Old 07-11-2007, 12:01 PM   #13 (permalink)
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I used Suzuki Sidekick rotors, Subaru front calipers and made my own brackets.

The 93 Subaru Loyale front calipers have a mechanical lever for e-brake and the Suzuki rotors have the same bolt pattern as the Ford axle and fit the Subaru calipers. When everything is all together, the bracket is just a flat piece of plate and no shimming or welding is required.
Hi Sean,

I did the same conversion in a CJ7 and I am courious to know the following:

What kind of master cylinder are you using (Could you please specify) ?
What did you do with the proportioning or combination valve??

Mario

Last edited by Mario Cerda; 07-11-2007 at 12:02 PM.
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Old 07-11-2007, 10:19 PM   #14 (permalink)
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Off an old lincoln mark VII if (78ish) i remember correctly. The middle picture is the lincoln caliper and rotor and the right is a 81 caliper and 92 4wd rotor (front brakes from f-150s) the calipers are direct replacements for each other (the lincolns have ebrake where the trucks ones donot which could be bad), the truck rotors are slight larger in diameter (like a 1/4 i think) but the caliper brackets are a 2 piece (very strong though) setup and as such you unbolt the two halves and then use a couple 1/8 washers (grade 8 or whatever and some new bolts) to space it out, the flange that the calipe slides overr may need to be taken down with a grinder (get a budddy to sping the opposites axle, be sure the rear end is kept together, then rest a grinder on the flange and go till the caliper slides over nicely.) then bolt everything together and you're good to go other than putting in the mc you got from the car you took the brakes from.

I snagged mine for a 100 bucks, and other than rebuilding the calipers new rotors and pads and playing with the brake lines this is a fairly cheap way to do it.
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Old 07-12-2007, 01:53 AM   #15 (permalink)
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Wait so lincoln calipers, ford truck front rotors, truck caliper brackets?
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Old 07-12-2007, 06:45 AM   #16 (permalink)
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Hi Sean,

I did the same conversion in a CJ7 and I am courious to know the following:

What kind of master cylinder are you using (Could you please specify) ?
What did you do with the proportioning or combination valve??

Mario
Hi Mario,

The 9" is going under a Suzuki Samurai so I was going to use the master from a 4 door Sidekick. The front axle is going to be a HP Dana44 with discs so I wanted a master that would bolt up to the firewall without any modification. The 4 door Sidekicks/Trackers have bigger brakes than the 2 door models and will be able to power the D44 and 9" with the disc conversion. They will also be power assisted and apparently I might not have to run a residual valve for the rear as others have done this before and they claim it works.

Another option, ironically, is a CJ or YJ master which I am told has the same bolt pattern as the Suzuki ones. You might be OK with your stock master but you may need to plumb a residual valve into the rear circuit and if needed a proportioning valve after it. (or just a combo valve) My application is a rock buggy so I'm not too worried about a proportioning valve at all. The stock components will all be replaced in my case.

Here is a little info on how to plumb disc/disc setups.
http://www.hot-rod.com.au/builder/brakes.html


Sean
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Old 07-12-2007, 08:26 PM   #17 (permalink)
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Hey Mustange70!,
I'm working on that same set up for my Bronco.
What Brake pads did you use with yours?
The Lincoln ones, or ones from the Ford F150 also like the rotors?
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Old 07-12-2007, 10:02 PM   #18 (permalink)
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Hey Toughguy, do you need me to send you some better condition 9" housings? The one in the pic looks so pitted that you should be topping off gear oil once a week....

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Old 07-12-2007, 10:06 PM   #19 (permalink)
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Quote:
Wait so lincoln calipers, ford truck front rotors, truck caliper brackets?
Almost, lincoln caliper brackets, trucks rotors and calipers (if i want too, but this is a street trucks they're going on so i want to keep the ebrake, so rebuilt lincoln calipers but you can go the other way if you want to).

Haven't got to far with this, still just a pile of parts, but if i remember right i think i can use the truck pads which is what i want to do cause they're cheap, i also will be using an inline wilwood porp. valve cause my truck is lighter in the rear than the lincoln and the lincoln p-vavle is probably setup for that so i'll need to turn down the pressure. i';; look at the parts this weekend when i go back to the farm for the weekend.
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Old 07-12-2007, 11:11 PM   #20 (permalink)
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i checked tonight... the factory 78-79 F150 front dana 44 rotors fit really nice on my Moser 35 splines. ill have to make the shims, but i was surprised they cleared without grinding...
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Old 07-13-2007, 12:21 AM   #21 (permalink)
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Hey Toughguy, do you need me to send you some better condition 9" housings? The one in the pic looks so pitted that you should be topping off gear oil once a week....

Looks like hammered paint or rhinoliner to me.
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Old 07-13-2007, 12:33 AM   #22 (permalink)
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I just use some stock explorer brackets, calipers, and rotors, just redrill the rotors to the right pattern or buy them from currie. Cheap and Easy, $150 and your set with E-brake and parts are easy to find/get at most junkyards and 100% bolt on.
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Old 07-13-2007, 06:38 AM   #23 (permalink)
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Hey Toughguy, do you need me to send you some better condition 9" housings? The one in the pic looks so pitted that you should be topping off gear oil once a week....

Yeah well this came off an '80 F150 that spent its life in Northern Ontario. We pave the roads with salt here every winter and it just eats everything. It's still solid enough though....................I hope!

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Looks like hammered paint or rhinoliner to me.
Sorry TJ, that really is rust pitted. I think the black paint makes it look worse than it really is but thanks for the idea. I'll just spray-bomb it with that hammered paint and tell everybody it's supposed to look like that!


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Old 06-05-2008, 08:27 PM   #24 (permalink)
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I just use some stock explorer brackets, calipers, and rotors, just redrill the rotors to the right pattern or buy them from currie. Cheap and Easy, $150 and your set with E-brake and parts are easy to find/get at most junkyards and 100% bolt on.
and this went on a big bearing rear end??
if so how did you shim the bearing to stay in place???

the stock plate is like 1/8" and the explorer one is like 3/8" that is alot of play for that axle bearing to play in...
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Old 06-05-2008, 09:49 PM   #25 (permalink)
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You can buy the shims from Currie or do what I did and cut up a old bearing and make your own.
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