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Old 04-03-2011, 03:32 PM   #1 (permalink)
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Easy disc brake conversion

Ok Guys, Not sure if anyone else has covered this in this manor but I want to look at a new option for EASY disc brake conversion. This was on my offroad buggy. (91 Truck)





So. I went to autozone and purchased 2001 montero sport rotors 4wd, REAR. they have 180mm centers and 6 on 5.5 and fit PERFECTLY. You can use the same vehicles calipers from junkyard as well. Or Isuzu trooper or Pathfinder/Montero Sports.

We took 3/8" plate set our pattern for axle tube bolts and made a quick measurement for ride height on caliper retainer, cut the steel, drilled it and shimmed it out for center of rotor using washers. WALA I have $85 and 2 hours in rear disc brakes. BTW.. No brake line adapters needed. These calipers were double flare also like Toyota (I used nissan pathfinders 1994 rear)

Step By Step:
Pull axle from truck
Remove all mechanics from old drum brakes. Pull all 4 axle retaining bolts on each side. Slide individual axles loose and setup to cut with plasma or torch. You will need water or a thermal brake liquid OR you can totally dissasemble the axle to protect bearings/seals. (Or you can take your chances).. Cut backplate tight around axle flange (where 4 bolts are)

Re-install each axle ONLY putting nuts on the bottom 2 bolts. Remove top 2 bolts (using a hammer pound studs out)

Go buy you some 2 1/2" grade 8 3/8" bolts, lock washers, and nuts. Also buy an assortment of flat washers (needed to shim)

Stick a bolt in each of the top 2 holes with the bolts going towards the center of axle. (tack welding the bolts to axle flange is easiest)

Cut a piece of 3/8" Plate to hold caliper retainer over rotor (From memory I believe the top spread for caliper was 5.125", spread on axle flange was 3.5 and they were on an angle seperated by 2.25" center to center. You are going to need to cut an arch in the plate for the axle tube and an arch on top for the caliper to drop basically making a "H" shape.

Installing the plate to the back of axle flange using a small stack of washers for shiims. I beleive it was 3 washers totally 3/16 to 1/4" which centered it perfectly. Then place plate, lock washer and nut.

Install rotor to axle. (2001 Montero Sport 4wd Rear Disc rotor)

Install Retainer using bolts from junkyard donor.

Install caliper and connect brake hoses. (using flexible hose from junkyard donor connect to hard line from drums)

Wala - Bleed and enjoy..

Disc brake conversion done for less that $100 !!!!

Last edited by isophase; 04-03-2011 at 04:42 PM.
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Old 04-03-2011, 03:42 PM   #2 (permalink)
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nice! belongs in the facts.....one question, any issues w/ rim clearance
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Old 04-03-2011, 03:44 PM   #3 (permalink)
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You say you used 1994 Pathfinder rear calipers?

Do they have provisions for an e-brake?
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Old 04-03-2011, 03:45 PM   #4 (permalink)
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Do these include a provision for a parking brake?
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Old 04-03-2011, 03:49 PM   #5 (permalink)
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There is no provision for e brake because I chose not too.. You could find a caliper that had e brake like the trooper. This setup fits in a 15" wheel!!!!
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Old 04-03-2011, 03:50 PM   #6 (permalink)
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$35 for a line lock is a simple quick fix and better in my opinion.. FLip a switch and your locked up
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Old 04-03-2011, 04:21 PM   #7 (permalink)
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Pic with a 15" wheel to show clearance?
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Old 04-03-2011, 04:42 PM   #8 (permalink)
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Added your pic requests to post smewhtguy
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Old 04-03-2011, 04:48 PM   #9 (permalink)
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Sweet, good tech.
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Old 04-03-2011, 05:57 PM   #10 (permalink)
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Quote:
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$35 for a line lock is a simple quick fix and better in my opinion.. FLip a switch and your locked up
Except it won't pass anywhere where you need a parking brake for inspection. Looks like a pretty good setup for a trail rig, though.
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Old 04-03-2011, 08:33 PM   #11 (permalink)
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Nice job and thank you for contributing some tech
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Old 04-03-2011, 08:52 PM   #12 (permalink)
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This is awesome info, this proves there is still a few of the researchers and builders out there that can contribute. Thanks.
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Old 04-04-2011, 05:12 AM   #13 (permalink)
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does the stock master cylinder push enough fluid for these?
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Old 04-04-2011, 05:41 PM   #14 (permalink)
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My truck is the IFS MC with the 1" Bore. Although not tested im expecting it to be fine.. BUT I will let you know if this isnt the case. Worst case scenario, JUnkyard and a 1 ton chevy MC.. Fabricate the adapter..
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Old 04-06-2011, 06:40 PM   #15 (permalink)
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btt
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Old 04-06-2011, 06:51 PM   #16 (permalink)
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one thing to add you say pull axels loose i hope you pulled the entire axel out of the tube and did not just let it hang half way out this will ruin the axel seal and it will now leak when you drive the truck again just a heads up for anyone else doing this swap
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Old 04-06-2011, 07:25 PM   #17 (permalink)
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great tech. This looks like the way to go....

this needs to be in the FAQ
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Old 04-06-2011, 10:16 PM   #18 (permalink)
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I started on this setup a few years ago, but never finished. If I recall correctly, my wheel studs (90rear axle) had a shoulder on them that required me to drill out the Montero rotor lug holes to the next size up. No big deal, and only took a few minutes for both rotors. I believe I also tried the Isuzu calipers, and they hit my 15" wheels. My wheels are aluminum, and yours appear to be steel. Basically, fitting inside a 15" wheel may depend on the wheel itself. At any rate, I'm glad you did this, as I may have to do it myself so I can use that montero rotor that has been sitting in the garage for the last few years. Oh, and by the way, Mitsubishi has a Montero Sport, and a Montero. The Montero uses different rotors that will not work. Just to restate the original post, ask for Montero SPORT rotors.
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Old 04-07-2011, 07:13 AM   #19 (permalink)
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can you post pics looking front to back or back to front so that we can see your bracket mounting on the axle?
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Old 04-07-2011, 08:39 AM   #20 (permalink)
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That was a good write up. I'm glad you said to use montero sport rotors. I was going to use trooper calipers because of the ebrake. But the trooper rotors won't fit. I was going to turn the hub of my axle down slighty until the trooper rotor would fit over. I think your ideas better though.
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Old 04-10-2011, 05:43 PM   #21 (permalink)
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Ya. I have friends that have done just that.. They ended up paying $20 for the machine shop... For that and the cost of other rotors.. This is a in-out deal.. Bolts right up.

Should have my rig running in the next couple weeks.. Will let you know how well this setup is..
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Old 04-10-2011, 05:43 PM   #22 (permalink)
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Muttrk, its literally right off the back side of the top 2 axle flange bolts.. with I believe 3 stacked washers
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Old 12-17-2011, 10:38 PM   #23 (permalink)
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any updates on this?
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Old 12-18-2011, 06:48 AM   #24 (permalink)
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very nice! i wish i had read this before buying the TT kit... but ive got it now.

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Old 12-28-2011, 05:44 PM   #25 (permalink)
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Only Update- Works PERFECT.. stops amazing.. can hold it on the steepest hills Indiana has to offer.
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