Rear Disk Brake Conversion Pt 1

[rick996]

i want to do the tundra big brake upgrade on my prado90 so i read a lot about the similarities between the 3rd gen 4runner and 2nd gen prado 90 ....there are members in the prado poin club who have successfully converted there prado to part time 4wheel drive using the 4runner 4wd t case (the prado only come in all time 4wd) the 4runner t case bolted right on
see the thread on prado point
My Part time 4wd conversion
fyi in the thread above they say 185 surf which is the japanese and asian name for the 4runner

 

[ATX3rdGen]

I believe you might be able to get the parts from amayama. I've got couple parts numbers from the toyo diy website quoted earlier, but I don't want to bite the bullet and buy OEM calipers on a unproven concept haha.

Good call, I will check it out. I have found the calipers for a decent price, the real gap seems to be the parking drum brake parts. I found a kit the includes backing plates, bearings, bearing housing etc. just haven't delved into the parking brake parts.

I am going to ping some of my contacts in the auto world to see if I can get someone to pull a full setup off a truck. I have a contact that specializes in VAG parts, but, they have monthly deliveries and people overseas that pull parts. I worry trying to assemble individual parts would be cost prohibitive.

Until then, new axle bearings and brakes (all OEM) should hopefully take care of my pulsating rear brakes.

 

[Kelevra]

I worry trying to assemble individual parts would be cost prohibitive. .

I'm looking to return to Costa Rica shortly, any idea what parts I could look for and bring back? (ie parts I cannot get in the States for example).

Thanks.

 

[Trojan4x4]

Good call, I will check it out. I have found the calipers for a decent price, the real gap seems to be the parking drum brake parts. I found a kit the includes backing plates, bearings, bearing housing etc. just haven't delved into the parking brake parts.

I am going to ping some of my contacts in the auto world to see if I can get someone to pull a full setup off a truck. I have a contact that specializes in VAG parts, but, they have monthly deliveries and people overseas that pull parts. I worry trying to assemble individual parts would be cost prohibitive.

Until then, new axle bearings and brakes (all OEM) should hopefully take care of my pulsating rear brakes.

I'm thinking of doing montero/ford rear brake, if your interested I can send you my rear shoes (bendix), rear drums (machined) and all new hardware. About 5000 miles on them, did axle seals not so long ago

 

[jkeith.w]

Good call, I will check it out. I have found the calipers for a decent price, the real gap seems to be the parking drum brake parts. I found a kit the includes backing plates, bearings, bearing housing etc. just haven't delved into the parking brake parts.

I am going to ping some of my contacts in the auto world to see if I can get someone to pull a full setup off a truck. I have a contact that specializes in VAG parts, but, they have monthly deliveries and people overseas that pull parts. I worry trying to assemble individual parts would be cost prohibitive.

You have my attention.

 

[WrenchTech]

I'm in the middle of rebuilding my 1993 xtra cab pick up truck. I live in the rust belt so I have to deal with some corrosion issues. The drum brake backing plates on the rear axle definitely needed to be replaced. I scored a good deal on some rust-free used backing plates and was just starting out, but when I pulled of the drums I realized that all the brake hardware would have to be replaced too if I was going to do the job right. I had thought about doing a disc brake upgrade, but was hesitant to do it if it didn't include and e-brake provision.

I'm glad I stumbled across this thread. I think this is the solution I was looking for. And if I like it on my 93 I'll probably go ahead and do it on my first-generation 4runner as well.

 

[Rockdawg84]

I'm in the middle of rebuilding my 1993 xtra cab pick up truck. I live in the rust belt so I have to deal with some corrosion issues. The drum brake backing plates on the rear axle definitely needed to be replaced. I scored a good deal on some rust-free used backing plates and was just starting out, but when I pulled of the drums I realized that all the brake hardware would have to be replaced too if I was going to do the job right. I had thought about doing a disc brake upgrade, but was hesitant to do it if it didn't include and e-brake provision.

I'm glad I stumbled across this thread. I think this is the solution I was looking for. And if I like it on my 93 I'll probably go ahead and do it on my first-generation 4runner as well.

good luck and keep us updated on how it goes. :snacker:

 

[WrenchTech]

Just playing around with Sketchup I tried modeling a bracket based on what I've seen here in this thread and also what I've seen of a commercial product that trys to do a similar thing. I came up with this. Of course I don't know how thick the stacks of washers are in the set up that is the subject of this thread. I'm estimating 3/8” (0.375”). My prototype here is basically a sandwich of two layers, a 3/8” spacer and the quarter inch mounting plate

 

[WrenchTech]

It looks like a couple wrecking yards near me have the caliper. I'd like to grab just one for as little money as possible to experiment with. The Mitsubishi Montero rotor is a different story, there are not too many of those lying around in junkyards, but Rock Auto has quite a selection with the cheapest one at around $22 plus $10.99 shipping. I'm going to take a gamble and go ahead and order two rotors because the shipping is the same whether I order one or two. Brick-and-mortar part stores near me, O’Reilly, AutoZone, Napa, Advance Auto all want about $45 per rotor, so I will save roughly $35 by ordering online.

If the brackets come out alright and everything lines up I will order calipers, brake hoses (Mustang front hoses), pads and two Ford parking brake cables. I'm going to go for the parking brakes right away. I noticed that Rock Auto has Ford Mustang parking brake cables for just a little bit over $10. These are 72 inch long cables! I plan to shorten the Ford cables and attach them to my existing Toyota cables after some modification. It doesn’t look like it's going to be too difficult.

Including steel, miscellaneous hardware and consumables, the materials for this project should cost me no more than $300. If I find that I need a new master cylinder, residual valves and/or a proportioning valve, then of course I will have to pay more.

 

[Sean K.]

So what's the consensus on the master cylinder with the disc brakes? Too small or is it okay? What are people swapping in if they wanted a bigger one?

Not doing the swap yet....but my booster took a crap and now I'm debating spending $300-800 on a new booster (going try changing the cheaper check valve first assuming Toyota will sell it separately even though it seems to be working correctly....hoping it's intermittently failing) and don't want to buy a new one and then have to replace it when I get around to the solid axle and disc brake swap.

 

[Rockdawg84]

Sean I have been running the stock MC for 6 years now with Tundra calipers up front and Mustang rears and have no problem at all. It is a little softer than stock but hardly noticeable. I now have a 2000 stock Runner and don't feel a big difference between it and my 98 on 35's. I don't think you have anything to worry about. BTW with no rear ABS I have no problem locking the rear up at will.

Not sure if you've seen this but it is an interesting short read.

Another Master Cylinder Option... - Pirate4x4.Com : 4x4 and Off-Road Forum

So what's the consensus on the master cylinder with the disc brakes? Too small or is it okay? What are people swapping in if they wanted a bigger one?

 

[Sean K.]

Sean I have been running the stock MC for 6 years now with Tundra calipers up front and Mustang rears and have no problem at all. It is a little softer than stock but hardly noticeable. I now have a 2000 stock Runner and don't feel a big difference between it and my 98 on 35's. I don't think you have anything to worry about. BTW with no rear ABS I have no problem locking the rear up at will.

Not sure if you've seen this but it is an interesting short read.

Another Master Cylinder Option... - Pirate4x4.Com : 4x4 and Off-Road Forum

Thanks for the link....that looks to be the best option due to the size.

 

[WrenchTech]

good luck and keep us updated on how it goes. :snacker:

So after some delay, I finally have some Mitsubishi Montero rotors in hand. And tomorrow my wrecking yard calipers should be available to pick up. On my way to the wrecking yard I will stop by a recycling company, that has been a good source of steel for me, and look for some quarter inch flat stock to make some brackets.

Now that I'm getting ready to begin I have a question: Why did you cut the bearing cup out of the brake backing plate leaving that ring of sheet metal attached to it? Why not just press the bearing cup out and use it by itself? I don't see the sheet metal serving any purpose.

 

[Jaysen4runner]

My prototype 3gen 4runner rear disc with ebrake park brake. All Toyota parts expect for the custom bracket. Working with the ebrake line as we talk, 3gen 4runner ebrake brake only used 1 cable. The new setup require 2 cable line (Y) into the hand brake. Quick teaser pic of the bracket, will update as I start to get all my parts in.

 

[WrenchTech]

My prototype 3gen 4runner rear disc with ebrake park brake. All Toyota parts expect for the custom bracket. Working with the ebrake line as we talk, 3gen 4runner ebrake brake only used 1 cable. The new setup require 2 cable line (Y) into the hand brake. Quick teaser pic of the bracket, will update as I start to get all my parts in.

Looking forward to seeing what your setup is all about.

 

[Jaysen4runner]

Basically it's a 4th gen 4runner OEM setup but on the 3gen 4runner

 

[midcoma]

I successfully changed my rear brakes to disc using Mustang calipers and 4th Gen 4Runner rotors. Made a custom bracket that I can provide CAD drawings for. Bracket was cut from 1/2" plate and had some material removed from the mounting locations to center properly. I'd have to check on how much material was removed.

For the master cylinder I did have a very soft pedal with Tundra brakes up front and Mustang calipers in the rear. I used a master cylinder from a F350 to increase bore to 1.125". Very little modification to mount up.

I'll have to find all the details and post the info for anyone interested.

 

[coronan]

Interested.

 

[WrenchTech]

Interested.

..x2

 

[jkeith.w]

Basically it's a 4th gen 4runner OEM setup but on the 3gen 4runner

I ran across this thread on YotaTech - not sure if he completed the conversion?