Easy disc brake conversion

[OOP'S]

Originally Posted by Dychen

OOPS: Did you modify a set of Dave'z rear brackets to make that?

Yes.

[jersummers]

The setup I just put together looks very close to OOP'S set up. I used 2000 Isuzu Trooper rear rotors (they had the drum type e-brake.) I mated them with 1995 Montero Sport calipers (no e-brake.) I already had Davez brackets so I modified them to make everything fit.

It was half off day at the pick n pull so the rotors and calipers combined only cost $33 ($45 before core returns.) I'll have to replace the rotors in a bit, but for a test fit and a little use it will be worth it.

I do know that the calipers from the Trooper were almost identical to the Montero Sport, the Montero Sport calipers were a little cleaner and pads were nearly new which is why I took those home instead of the ones from the trooper. Also, the factory 15" Aluminum Toyota rim will not fit over the set up. My 17" steels fit fine. I don't know if 15" or 16" steels wouls work since I don't have any to test.

[257speed]

Made it to the local u-pull it today. Found a 1997 Montero. Got the rotors and calipers (with good pads), along with a toyota v-6 booster and master cylinder, all for $79.00. Need to order some new axle seals from Marlin, a proportioning valve and a line lock, then do the swap. Can't wait.

[257speed]

So I finally got to work on mine. Rotors and calipers are off a '97 Montero sport. The brackets are 1/4" plate, doubled on top for the offset. While I had it apart, I threw in a Marlin seal kit.
Jig I made to press the bearings off the axle

Bracket

Rotor mounted

Caliper mounted and centered


And with the wheel mounted

In this picture, you can see the cool little scraper to clear mud from the rotor before the pads catch it.
Just FYI, this is with a 15" steel wheel, not enough clearance for a 15" aluminum wheel

[TBItoy]

Originally Posted by 257speed

So I finally got to work on mine. Rotors and calipers are off a '97 Montero sport. The brackets are 1/4" plate, doubled on top for the offset. While I had it apart, I threw in a Marlin seal kit.
Jig I made to press the bearings off the axle
[And with the wheel mounted

In this picture, you can see the cool little scraper to clear mud from the rotor before the pads catch it.
Just FYI, this is with a 15" steel wheel, not enough clearance for a 15" aluminum wheel

Did you use the stock axle bearing housing studs?

Could you have used a single 1/4" plate bracket had you not put the stock nuts on first? (I figure the stock nut is thicker than 1/4"?)

[MT-Toy]

Some of the Old Hats correct me if I'm wrong, but I seem to remember ORC (before PBB) users putting together a homebrew kit from Rodeo rear brake parts. Parking brake and all too. 95?-'99?

[257speed]

Originally Posted by TBItoy

Did you use the stock axle bearing housing studs?

Could you have used a single 1/4" plate bracket had you not put the stock nuts on first? (I figure the stock nut is thicker than 1/4"?)

I used one of the stock studs for the hole where the plate does not attach. The other 3 are 3/8x16 grade 8 bolts. I guess you could, but this way, you have a good tight nut holding on the axle and then another for the bracket.

Originally Posted by MT-Toy

Some of the Old Hats correct me if I'm wrong, but I seem to remember ORC (before PBB) users putting together a homebrew kit from Rodeo rear brake parts. Parking brake and all too. 95?-'99?

These are rotors from a '97 montero, which is pretty similar to the rodeo. It did have an internal e-brake. I need to look into it to see how/if it could be used.

[OOP'S]

Originally Posted by MT-Toy

Some of the Old Hats correct me if I'm wrong, but I seem to remember ORC (before PBB) users putting together a homebrew kit from Rodeo rear brake parts. Parking brake and all too. 95?-'99?

I remember that write up, I am using calipers off a Honda Passport, same thing as the Rodeo and Montero discs. Did not worry about the parking because I have the A-P t-case brake.

[jersummers]

Originally Posted by TBItoy

Did you use the stock axle bearing housing studs?

Could you have used a single 1/4" plate bracket had you not put the stock nuts on first? (I figure the stock nut is thicker than 1/4"?)

The nut is closer to 1/2" thick. I did mine opposite where the plate is mounted on the rear of the axle housing and the modified offset part (that mounts to the caliper) has to offset away from the caliper for proper fit. I also used 1/4" plate.

[MT4Runner]

Originally Posted by rockdawg84

You inspired me to do this conversion on my 98 runner. Because its my daily driver I chose to go with a caliper that had a mechanical e-brake. 98 mustang GT rear caliper. Because I bought everything new it was a little more than $100 but totally worth it.

haven't got the e-brake hooked up yet but it should not be too hard.

Mid-90's Ford Tauruses have similar rear calipers with the built-in parking brake. ~95-earlier were solid rotor, 95-up were vented rotor.

Originally Posted by red-gt'r

It looks like the ebrake lever gets pulled vertically down to engage? That'll take some MacGuyvering to get working eh?

Ford had a sheathed cable. The end of the sheath stops at that little guide below the parking brake arm. If you use this setup, the easiest way would be to grab the parking brake cables off the donor car and adapt it to the open cable up inside the framerail at the "bell crank" in front of the Toy fuel tank.

[bbtank45]

Reviving an old thread...


So, ive fabbed up my modified Davez Bracket and ive run into one issue....

Im using:

1) 2001 Montero Sport Rear Rotors
2) 1994 Nissan Pathfinder Calipers
3) Modified Davez Bracket using 3/8" steel

I cannot get a bolt that will hold the caliper to the bracket, does any1 know the proper bolt to be used on this caliper? Ive tried 3/8 and M8 & M10.

Any help is appreciated, thanks

[jkief86]

I just did this swap using a 95 Montero LS. It works great. I went overkill and used 3/8"s for the bracket. I had no offset, and it looked great at first, the stock bearing retainer bolts worked too. After driving it a while, I need to file an 1/8" off the ends of the caliper bolts or add 1/8" of washers to the axle end of the bracket. The bolts are currently dragging on my rotor, barely.

[OOP'S]

Nice job, the reason they are draging is your caliper is not centered on the rotor.

[jkief86]

It cleared when I fit it all the first time. I'm actually surprised how much a "semi-float" actually floats There was easily 3/16" between the bolts and the rotor when I installed them.