Easy disc brake conversion - Pirate4x4.Com : 4x4 and Off-Road Forum

isophase · 04-03-2011, 03:32 PM

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 !!!!

jklmc · 04-03-2011, 03:42 PM

nice! belongs in the facts.....one question, any issues w/ rim clearance

toyminator2000 · 04-03-2011, 03:44 PM

You say you used 1994 Pathfinder rear calipers?

Do they have provisions for an e-brake?

PAToyota · 04-03-2011, 03:45 PM

Do these include a provision for a parking brake?

isophase · 04-03-2011, 03:49 PM

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!!!!

isophase · 04-03-2011, 03:50 PM

$35 for a line lock is a simple quick fix and better in my opinion.. FLip a switch and your locked up

smewhtguy · 04-03-2011, 04:21 PM

Pic with a 15" wheel to show clearance?

isophase · 04-03-2011, 04:42 PM

Added your pic requests to post smewhtguy

smewhtguy · 04-03-2011, 04:48 PM

Sweet, good tech.

PAToyota · 04-03-2011, 05:57 PM

Quote:

Originally Posted by isophase

$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.

4xflyin · 04-03-2011, 08:33 PM

Nice job and thank you for contributing some tech

R.DesJardin · 04-03-2011, 08:52 PM

This is awesome info, this proves there is still a few of the researchers and builders out there that can contribute. Thanks.

800MJ · 04-04-2011, 05:12 AM

does the stock master cylinder push enough fluid for these?

isophase · 04-04-2011, 05:41 PM

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..

isophase · 04-06-2011, 06:40 PM

btt

yotaneck13 · 04-06-2011, 06:51 PM

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

MattyB4x4 · 04-06-2011, 07:25 PM

great tech. This looks like the way to go....

this needs to be in the FAQ

Unclejesse88 · 04-06-2011, 10:16 PM

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.

Muttrk · 04-07-2011, 07:13 AM

can you post pics looking front to back or back to front so that we can see your bracket mounting on the axle?

TeepeeCreeper · 04-07-2011, 08:39 AM

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.

isophase · 04-10-2011, 05:43 PM

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..

isophase · 04-10-2011, 05:43 PM

Muttrk, its literally right off the back side of the top 2 axle flange bolts.. with I believe 3 stacked washers

Unclejesse88 · 12-17-2011, 10:38 PM

any updates on this?

mikepotts · 12-18-2011, 06:48 AM

very nice! i wish i had read this before buying the TT kit... but ive got it now.

FAQ!
FAQ!
FAQ!

isophase · 12-28-2011, 05:44 PM

Only Update- Works PERFECT.. stops amazing.. can hold it on the steepest hills Indiana has to offer.

04-03-2011, 03:32 PM	#1 (permalink)
isophase Registered User Join Date: May 2010 Member # 160632 Posts: 66	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.

04-03-2011, 03:45 PM	#4 (permalink)
PAToyota Pirate4x4 Addict! Join Date: Oct 2004 Member # 37600 Location: South Central Pennsylvania Posts: 6,386	Do these include a provision for a parking brake? __________________ GET INVOLVED - Join the Blue Ribbon Coalition SIGN THE PETITION - SAVETHEHAMMERS - #85 '93 Chevrolet 6.5TD K2500 NV4500 Std. Cab Longbed 170K '85 Toyota 22R RN60 4x4 Std. Cab Shortbed 178K (Currently retired for rebuild)

04-03-2011, 04:21 PM	#7 (permalink)
smewhtguy White Trash Fab Join Date: Oct 2007 Member # 100827 Location: stafford Va Posts: 6,367	Pic with a 15" wheel to show clearance? __________________ "If you are gonna live life on the edge you better have good balance" 06 Tundra DC The "Trifecta" 3 seat yota buggy http://pirate4x4.com/forum/showthread.php?t=1027210 http://www.AddictedOffroad.com/ www.ruffstuffspecialties.com http://f-o-a.com

04-03-2011, 04:48 PM	#9 (permalink)
smewhtguy White Trash Fab Join Date: Oct 2007 Member # 100827 Location: stafford Va Posts: 6,367	Sweet, good tech. __________________ "If you are gonna live life on the edge you better have good balance" 06 Tundra DC The "Trifecta" 3 seat yota buggy http://pirate4x4.com/forum/showthread.php?t=1027210 http://www.AddictedOffroad.com/ www.ruffstuffspecialties.com http://f-o-a.com

04-03-2011, 08:52 PM	#12 (permalink)
R.DesJardin Shifting for all Join Date: Feb 2006 Member # 68266 Location: Arlington, WI Posts: 1,202	Swaps This is awesome info, this proves there is still a few of the researchers and builders out there that can contribute. Thanks. __________________ *RADesigns Products LLC - Shift to the Best* The 2nd Amendment is not to be screwed with, I am a card carrying member of the NRA. If this offends you please don't buy my products. http://radesignsproducts.com/Accessories.html Jeep, Toyota and Nissan automatics, Shift controllers and shifters, Toyota Triple Stick levers! My stuff: /forum/toyota-truck-4runner/996438-2rz-82-w-a340-duals-radesigns-way.html John 3:16- He is the answer.

04-03-2011, 03:42 PM	#2 (permalink)
jklmc Registered User Join Date: Jul 2010 Member # 164153 Location: GUAM Posts: 63	nice! belongs in the facts.....one question, any issues w/ rim clearance

04-03-2011, 03:44 PM	#3 (permalink)
toyminator2000 Registered User Join Date: Sep 2007 Member # 99025 Posts: 259	You say you used 1994 Pathfinder rear calipers? Do they have provisions for an e-brake?

04-03-2011, 03:49 PM	#5 (permalink)
isophase Registered User Join Date: May 2010 Member # 160632 Posts: 66	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!!!!

04-03-2011, 03:50 PM	#6 (permalink)
isophase Registered User Join Date: May 2010 Member # 160632 Posts: 66	$35 for a line lock is a simple quick fix and better in my opinion.. FLip a switch and your locked up

04-03-2011, 04:42 PM	#8 (permalink)
isophase Registered User Join Date: May 2010 Member # 160632 Posts: 66	Added your pic requests to post smewhtguy

04-03-2011, 08:33 PM	#11 (permalink)
4xflyin Registered User Join Date: May 2005 Member # 48209 Location: West Hills, CA Posts: 458	Nice job and thank you for contributing some tech

04-04-2011, 05:12 AM	#13 (permalink)
800MJ Registered User Join Date: Dec 2005 Member # 64089 Location: CT Posts: 886	does the stock master cylinder push enough fluid for these? __________________ [QUOTE=roastbeef;10323284]last night, this girl was sucking my dick and she stated licking my balls and then she starteld likcing my ass. i almost nuttd right on top of her fucking head before i got to stick it in her. im drunk.[/QUOTE] [QUOTE=sucker;10784484]ok straight six and reliable don't go together. But have fun with that one.[/QUOTE]

04-04-2011, 05:41 PM	#14 (permalink)
isophase Registered User Join Date: May 2010 Member # 160632 Posts: 66	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..

04-06-2011, 06:40 PM	#15 (permalink)
isophase Registered User Join Date: May 2010 Member # 160632 Posts: 66	btt

04-06-2011, 06:51 PM	#16 (permalink)
yotaneck13 Registered User Join Date: Jan 2010 Member # 152631 Location: CRANBERRY PENNSYLVANIA Posts: 277	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 __________________ R.I.P Derek James Black 1995-2010 I miss you BUD!

04-06-2011, 07:25 PM	#17 (permalink)
MattyB4x4 Rock God Join Date: Jul 2004 Member # 32726 Location: Atlanta, GA Posts: 1,749	great tech. This looks like the way to go.... this needs to be in the FAQ __________________ 5/8 Yotabuggy - duals + 4.7, 5.29's, locked, 40's, linked rear/fox airs, shift knob ΜΟΛΩΝ ΛΑΒΕ

04-06-2011, 10:16 PM	#18 (permalink)
Unclejesse88 Registered User Join Date: Apr 2011 Member # 187757 Posts: 194	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.

04-07-2011, 07:13 AM	#19 (permalink)
Muttrk Registered User Join Date: Dec 2000 Member # 2568 Location: Alamogordo, NM Posts: 752	can you post pics looking front to back or back to front so that we can see your bracket mounting on the axle? __________________ 85 4Runner with a bunch of crap done to it

04-07-2011, 08:39 AM	#20 (permalink)
TeepeeCreeper Registered User Join Date: Nov 2009 Member # 146049 Posts: 65	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.

04-10-2011, 05:43 PM	#21 (permalink)
isophase Registered User Join Date: May 2010 Member # 160632 Posts: 66	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..

04-10-2011, 05:43 PM	#22 (permalink)
isophase Registered User Join Date: May 2010 Member # 160632 Posts: 66	Muttrk, its literally right off the back side of the top 2 axle flange bolts.. with I believe 3 stacked washers

12-17-2011, 10:38 PM	#23 (permalink)
Unclejesse88 Registered User Join Date: Apr 2011 Member # 187757 Posts: 194	any updates on this?

12-18-2011, 06:48 AM	#24 (permalink)
mikepotts Registered User Join Date: Oct 2007 Member # 101159 Location: east TN Posts: 952	very nice! i wish i had read this before buying the TT kit... but ive got it now. FAQ! FAQ! FAQ! __________________ 91 YJ stock and a 93'ish mustang... Yeah, its fast.

12-28-2011, 05:44 PM	#25 (permalink)
isophase Registered User Join Date: May 2010 Member # 160632 Posts: 66	Only Update- Works PERFECT.. stops amazing.. can hold it on the steepest hills Indiana has to offer.

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