Rear Disk Brake Conversion Pt 1

[MN4runnerman]

Here is the link to the thread and the OP posts a link to his build on pirate4x4. His link isn't working on my phone though so hopefully it does when I look at it on my computer later. As you can tell I'm proud of my job. http://www.toyota-4runner.org/3rd-gen-t4rs/210690-master-cylinder-booster-question.html

 

[4x4runner2002]

It isn't to hard and yes I had planned to put in spacers instead of the washers but never did. NOW this showed up today because I joined the bent rear axle shaft flange club.




So my plan is to run the brackets on the opposite side and weld on my own mount so I can still run my mustang calipers and Montero hats. Also I will finally get my ebrake installed. I just have to finish up two other projects that are taking up my whole carport. LOL. But hopefully I will begin to work on them by the end of the week.

do you think you bent the flange because of the rear brake conversion. I just ordered all my parts and got the brakes lines made today. ill be tackling the job following your thread.

i really appreciate you doing the write up and posting the dimensions of the bracket.

 

[Rockdawg84]

do you think you bent the flange because of the rear brake conversion. I just ordered all my parts and got the brakes lines made today. ill be tackling the job following your thread.

i really appreciate you doing the write up and posting the dimensions of the bracket.

No, for some reason 3rd gen 4runner axle flanges are soft and a lot of guys who are on 35's and wheel hard have bent them. The good news is that now my full float rear conversion is all the easier.

Good luck with your conversion. post up a link to your build and the conversion.

 

[4x4runner2002]

No, for some reason 3rd gen 4runner axle flanges are soft and a lot of guys who are on 35's and wheel hard have bent them. The good news is that now my full float rear conversion is all the easier.



Good luck with your conversion. post up a link to your build and the conversion.

I'm guessing you are on tapatalk. On the web view there is a link to my build in my sig. It's not the most updated but I'll put the conversion in it when I do it.

 

[runner4play]

Hi guys as it seems all the rear disc swap info is here... have any of you successfully swapped in FJ rear discs... I picked up a 2010 fj 8.2 elocker rear that I plan to sell, but it is complete from disc to disc. I've contemplated if there is such a thing as a simple swap over.... Thanks for any insight.

 

[legokcen]

So I don't have part II done yet but I am closing in on it. I have had several ask for the template for the caliper mounting plate.

Finally here you go

Do people need these fabricated? I have the ability and resources, that's why I ask. I may be able to get a few made if there is a demand.

 

[Rockdawg84]

Hi guys as it seems all the rear disc swap info is here... have any of you successfully swapped in FJ rear discs... I picked up a 2010 fj 8.2 elocker rear that I plan to sell, but it is complete from disc to disc. I've contemplated if there is such a thing as a simple swap over.... Thanks for any insight.

The issue is that you would have to cut the axle tubes and weld them onto your axle, since they ends are not a direct bolt on, and the overall axle width is to wide to fit without major reworking of the link brackets. not saying it can't be done just saying it can't be done easy:hatsoff:

 

[runner4play]

Rockdawg,

Thanks for your reply, it seems that's pretty much where it stands other than utilizing a full float setup like Front Range Offroad produces. Which given the reason I was hoping this could be a simple project with parts I already had..... that setup is no where near my budget. At this point i'm just gonna keep my drums and be happy.

 

[m_pallas123]

E-brake?

I'm going to do this in the next week or so once I can get those brackets made up. I still need to have those brake lines made up though. Are there any specific details about the existing brake line I'll need to know, diameter for instance? Also, beside the banjo connector on the flex line, are there any other connectors/adapters I'll need to connect to the existing brake line or the caliper?

Also, I see the e-brake write up is coming soon, but from those who have already done the conversion, are there any parts I'll definitely need to make the E-brake work?

I'm new here, but have used this forum repeatedly for various projects. Many thanks to all who contribute to increasing my knowledge!

 

[Rockdawg84]

I'm going to do this in the next week or so once I can get those brackets made up. I still need to have those brake lines made up though. Are there any specific details about the existing brake line I'll need to know, diameter for instance?

Make sure you have a good flare tool so you can modify the hard line. The stock lines are thick and can be hard to flare with a cheap tool.

Also, beside the banjo connector on the flex line, are there any other connectors/adapters I'll need to connect to the existing brake line or the caliper?

I just went to a company hose power with my caliper and the flare end (prior to flaring) told them I needed ends and a flex line. took them about 20min.

Also, I see the e-brake write up is coming soon, but from those who have already done the conversion, are there any parts I'll definitely need to make the E-brake work?

there are a lot of ways to connect the ebrake but I ordered the mustang ebrake cables and will modify the stock cable to go into the equalizer. (yes still on the bench waiting to happen)

I'm new here, but have used this forum repeatedly for various projects. Many thanks to all who contribute to increasing my knowledge!

Our Pleasure and good luck. Post up here pics of your install.

 

[poleclimber63]

It isn't to hard and yes I had planned to put in spacers instead of the washers but never did. NOW this showed up today because I joined the bent rear axle shaft flange club.

So my plan is to run the brackets on the opposite side and weld on my own mount so I can still run my mustang calipers and Montero hats. Also I will finally get my ebrake installed. I just have to finish up two other projects that are taking up my whole carport. LOL. But hopefully I will begin to work on them by the end of the week.

So I just spent the last 1.5 hrs reading your thread, very intriguing!
I have total respect for your efforts and creativity!!! Wow! I remember coming across your thread awhile back, but lost track.
Soooooo, can you put us out of our misery and post pictures of the E-brake setup??? PLEEEAAASE?

I recently completed a disc brake upgrade to my sons' Mitsubishi Eclipse GS(originally with drum brakes). I chose a simple swap with Eclipse GT disc brakes--- the only issue being the e-brake modification! Thank god for Dremel...
Due to the incredible improvement in braking response I started to speculate upon a simple upgrade to our rear brakes....I started a thread yesterday because I talked to a workmate who did a simple upgrade to his Dodge swapping wheel cylinders and increasing the wheel cylinder area 20-30%, substantially increasing braking capacity and response. He says its made all the difference while towing etc. Obviously, your mod would be, by far the way to go! Clearly, the cost investment ($600) is substantial, not to mention the time...:hiding:

By the way, how has your setup performed the last nearly 3 yrs, despite the bent axle shaft flange?

 

[m_pallas123]

Thanks so much for the reply Rockdawg.

Whipped out a prototype bracket and pulled a rear wheel off to get a better look at things...looks like I, like you, will be changing at least one axle seal. I changed the other side about a year ago and haven't put but a few thousand miles on it so hopefully it's nice and sealed up still. I didn't look at the other side for fear of too much bad news at one time. Anyway, I digress...
The diagram you posted up for the brackets, do those measurements take into account the correction for needing to re-drill one of those holes on the first one? Also, will drilling a whole larger to accommodate slight inaccuracies weaken the overall setup or allow for play/slippage that would end up throwing the caliper out of position?

I'm not the mechanic or the fabricator on this project, just the owner/laborer at the direction of those who know better so please, impart your knowledge upon me. In laymans terms

 

[poleclimber63]

updates!!??

Has anyone else done this upgrade??

Steps:
1 cutting the backing plate
2 fabbing caliper mounts
3 placing rotors from a 94 Montero Sport
4 placing Rear Caliper from 94-04 Mustang GT
5 Flaring brake lines and attaching flex lines to calipers

AND lastly, E-brake? Has anyone fabbed a reliable cable solution?

 

[noclinkers]

Do people need these fabricated? I have the ability and resources, that's why I ask. I may be able to get a few made if there is a demand.

If you send me an accurate scan, I will cut these on my CNC for cost of material plus shipping for all those who need them. I'm thinking it would not be more than around 5-7 bucks a pair at most.

 

[m_pallas123]

If you send me an accurate scan, I will cut these on my CNC for cost of material plus shipping for all those who need them. I'm thinking it would not be more than around 5-7 bucks a pair at most.

I would take you up on those. Still haven't found to time to make them.

 

[poleclimber63]

Hello?

Anyone done this upgrade lately??

Feedback from Rockdawg84, or anyone that did this upgrade back in 2012....any issues?

 

[Rockdawg84]

Anyone done this upgrade lately??

Feedback from Rockdawg84, or anyone that did this upgrade back in 2012....any issues?

not a single issue not even a set of pads yet still don't have the parking brake done but everything else has been great.

 

[TheHoneyBadger]

not a single issue not even a set of pads yet still don't have the parking brake done but everything else has been great.

I had read somewhere that the increased braking pressure from disc brakes would eat the bearings on semi-float axles and that was why toyota never gave us factory rear discs. You've been running them since 2012 though? A set of bearings every 4-5 years doesn't seem to bad. I wonder if the bearing wear isn't as much as it's made out to be.

Sent from my XT1254 using Tapatalk

 

[Rockdawg84]

I had read somewhere that the increased braking pressure from disc brakes would eat the bearings on semi-float axles and that was why toyota never gave us factory rear discs. You've been running them since 2012 though? A set of bearings every 4-5 years doesn't seem to bad. I wonder if the bearing wear isn't as much as it's made out to be.

Sent from my XT1254 using Tapatalk

I haven't heard that but I can say I've got a lot of miles and all of them are on 35's so I wouldn't worry about the bearings. :guitar3::guitar3:

 

[TorqueOfTheDevil]

All the best ones have rear disks!