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Old 01-22-2012, 12:08 AM   #1 (permalink)
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Rear Disk Brake Conversion Pt 1

So for the last couple of days I have been working on a project. I have needed to replace my rear axle seals for a while now and so this was a great chance. I also got a wild hair about doing a rear disk conversion. Based on a thread from the early toyota section. I began to do a lot of reading and research and I felt that I had enough info to tackle this on my own. I wish it was that easy but here I went.

First pull the axle shafts and do axle seals. Done

Next use a cutoff wheel or plasma cutter, or torch to cut around the mounting flange taking care not to put too much heat into the bearings and keep a fire extinguisher handy. rear axle oil is flammable.



I used the following parts. brake rotor from the rear of a 94 Montero Sport. Rear Caliper from 94-04 Mustang Gt. Custom flex line with banjo connector.







Next you have to remove 2 of the axle bolts. We used a air hammer, but it is possible to install the axle shafts and only bolt in the bottom 2 and then drive out the top 2. These will be replaced later.

Then you have to build a bracket to hold the caliper.

Here is my prototype



Here is the torched bracket made of 1/4" plate



cleaned up and drilled and painted



Now you have to shim the caliper bracket so the Caliper is centered on the rotor I used washers.



I cut and reflared the hard line to create a better angle for the flex line.



Bolt it all together, bleed the brakes and there you go.



Reinstall the tire and enjoy extra stopping power, Brakes that don't cake up in mud and snow, and you can work on the rear end with out cracking open the brake system.

I specifically chose the calipers because they have been around forever and I should have easy access to parts. Also the mustang weighs a little over 3000 lbs and so I thought that they would be a good balance for the front 13WL's. And they have a mechanical parking brake.

So a few thoughts now that I'm all done. Except the ebrake.

Pro's
1. super clean setup and stops wicked nice.
2. easy rear pad changes.
3. I can get into the rear axle with out breaking open the brake system. I hate bleeding the brakes just to change a 3rd member.

Cons
1. expensive and a lot of work to get it done. About $560 since I bought everything new.
2. I may need to upgrade my master cylinder because the pedal is a little softer than I normally like. Maybe a 1-1/16 bore or 1-1/8. I think this is partly because I have already moved up to the 13wls in the front and together with the rear calipers I could use the extra volume.
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Old 01-23-2012, 08:04 AM   #2 (permalink)
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looks good, but you could have saved a lot of time and money and just bought a disc conversion kit from bluey or ballistic or trail-gear....
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Old 01-23-2012, 09:39 PM   #3 (permalink)
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looks good, but you could have saved a lot of time and money and just bought a disc conversion kit from bluey or ballistic or trail-gear....
mostly because there are no kits on the market except for FROR that make a provision for a parking brake. (As Far A I Know). And honestly it was fun to figure out and make the bracket. Works like a charm so far.
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Old 01-23-2012, 09:50 PM   #4 (permalink)
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also this is pirate where we build stuff. granted all I built was the bracket. But I did build something. LOL
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Old 01-23-2012, 10:45 PM   #5 (permalink)
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Looks good! If you're having trouble with the e-brake cables, try using Control Cables Inc. I just completed my rear disc conversion using Maligu/G6 calipers and I had to run new cables from the leverage arm under the cab to the calipers. It was about 110 bucks for both cables and the hardware.
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Old 01-23-2012, 11:01 PM   #6 (permalink)
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Looks good! If you're having trouble with the e-brake cables, try using Control Cables Inc. I just completed my rear disc conversion using Maligu/G6 calipers and I had to run new cables from the leverage arm under the cab to the calipers. It was about 110 bucks for both cables and the hardware.
Thanks I will check them out
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Old 02-19-2012, 07:21 AM   #7 (permalink)
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That is awesome dude! I may have to do that on my junk!
C
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Old 02-19-2012, 12:14 PM   #8 (permalink)
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What did you do for a e-brake cable?
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Old 02-24-2012, 12:33 AM   #9 (permalink)
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I haven't yet. Been slammed with some other stuff but it needs to happen soon I miss my Ebrake.
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Old 02-25-2012, 10:07 AM   #10 (permalink)
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Quote:
Originally Posted by pclem View Post
looks good, but you could have saved a lot of time and money and just bought a disc conversion kit from bluey or ballistic or trail-gear....
If the other two kits are anything like TG's they may not work that good. They use a ridge mounted caliper where he used a floating caliper. I had problems with the setup I had using ridge mounted calipers. It worked fine on the street but on the trail I would have to pump the brakes. The problem was on a semi-float axle there is some flex in the bearing and the rotor would open up the caliper causing me to pump the brakes to get pedal.

I am just finishing up on a new setup that uses the 2001 Montero Sport rotors and Isuzu Trooper calipers which are a floating caliper. I modified the existing brackets from the old setup. It does not have an e-brake. I have maybe $200.00 in this setup, I did use used parts.
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Old 03-03-2012, 03:56 PM   #11 (permalink)
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Quote:
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Ok, fess up... did Venos make this??
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Old 03-03-2012, 09:51 PM   #12 (permalink)
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Ok, fess up... did Venos make this??
LOL if Kurt had helped me make that there wouldn't be an oblong hole. nope that was me and Mark did lend me a torch since somebody took the plasma cutter to Dallas I did pick up a set of tanks and torch hose but still need to get a torch. So yes I torched it out and then used the hand grinder to clean it up. I definitely need to get the drill press working and a new blade for the band saw.
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Old 03-06-2012, 06:42 PM   #13 (permalink)
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Well, I'm impressed. The sides look straight. Good work buddy! :P
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Old 03-12-2012, 11:19 PM   #14 (permalink)
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Thanks, flapper disk are the best, they clean up a lot.
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Old 09-17-2012, 11:43 PM   #15 (permalink)
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If the other two kits are anything like TG's they may not work that good. They use a ridge mounted caliper where he used a floating caliper. I had problems with the setup I had using ridge mounted calipers. It worked fine on the street but on the trail I would have to pump the brakes. The problem was on a semi-float axle there is some flex in the bearing and the rotor would open up the caliper causing me to pump the brakes to get pedal.

I am just finishing up on a new setup that uses the 2001 Montero Sport rotors and Isuzu Trooper calipers which are a floating caliper. I modified the existing brackets from the old setup. It does not have an e-brake. I have maybe $200.00 in this setup, I did use used parts.
This looks like a great setup. Any problems with it? How is it working?
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Old 11-16-2012, 11:26 PM   #16 (permalink)
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sorry for the delay in responding. It is working great. I have not had any problems or issues other than Im a slow ass about getting the ebrake hooked up.
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Old 09-28-2013, 01:19 PM   #17 (permalink)
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You ever get the ebrake hooked up?

...it's only been about a year or so.



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Old 09-29-2013, 11:02 PM   #18 (permalink)
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Quote:
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You ever get the ebrake hooked up?

...it's only been about a year or so.



C
I know I know I have the new ebrake cables and just need to build a couple of brackets and hook it all up. Soon my friend Soon.
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Old 01-10-2014, 12:49 AM   #19 (permalink)
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here is an update. still working great. getting closer to part II .

have had several people ask for this:


Just so you all know make sure that you build a templet out of wood or some other material because I had to elongate a bolt hole. Now was that because my drilling skills suck or because I cant transfer measurements I don't know but the measurements above are from my template.

first the plate with the elongated hole.


and the template that I built first.

just saying
I guess I can't measure
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Old 01-14-2014, 12:27 PM   #20 (permalink)
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Is the ebrake hooked up now?
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Old 01-15-2014, 11:01 AM   #21 (permalink)
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Good work, curious to see how you hook up the ebrake.
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Old 01-15-2014, 11:23 AM   #22 (permalink)
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Does a disk swap affect the LSPV in any way? I see come switching to a manual prop. valve.
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Old 01-15-2014, 11:05 PM   #23 (permalink)
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Quote:
Originally Posted by Mauzer View Post
Is the ebrake hooked up now?
not yet. I've got the parts just need to make the time.

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Good work, curious to see how you hook up the ebrake.
I will take lots of pics

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Does a disk swap affect the LSPV in any way? I see come switching to a manual prop. valve.
I have a 3rd gen Runner and don't have a LSPV but the disk brake conversion should not affect the LSPV in trucks that have them.
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Old 08-24-2014, 02:43 PM   #24 (permalink)
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E-Brake?

Hey RockDawg, you ever hook up the E-Brake I'm considering doing this setup and would love to see how it all turned out! Thanks in advance!
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Old 08-24-2014, 10:13 PM   #25 (permalink)
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I have all the parts sitting on the bench but no it's not on yet. sorry! I keep saying soon but honestly that really only applies in geologic terms. LOL
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