Page 1 of 2 12 LastLast
Results 1 to 15 of 27
  1. #1
    Join Date
    Sep 2017
    Location
    new york
    Posts
    26
    Chats
    0

    Default Rear disc brake conversion

    Has anyone done or heard of a disc brake conversion set up that worked well enough to be driven on daily?

    2000 xj 8.25 rear

    Sent from my SAMSUNG-SM-J727A using Tapatalk

  2. #2
    Pookapotamus's Avatar
    Pookapotamus is offline Level: Uber Jeep Cherokee Trailer Queen
    Join Date
    Dec 2011
    Location
    Calgary, AB, Canada
    Posts
    1,705
    Chats
    0

    Default Re: Rear disc brake conversion

    I have the terraflex kit on my d44, works great! 5000lbs xj and it stops on a dime! And yes I daily drive mine.


    Sent from my iPhone using Tapatalk

  3. #3
    Join Date
    Apr 2009
    Location
    Salem Va.
    Posts
    890
    Chats
    0

    Default Re: Rear disc brake conversion

    ZJ disc brakes will work. You need to drill some new holes and make the center hole in the backing plate slightly larger. A guy on our local forum did his , if I can find the write-up I'll post a link. Update...here is the link , pictures gone , starts at post 170 on page 17
    http://www.vaoffroadsports.com/forum...ld-Blue/page17

    Sent from a van down by the river
    Last edited by drakan1908; 09-26-2017 at 06:03 AM.

  4. #4
    Join Date
    Sep 2017
    Location
    new york
    Posts
    26
    Chats
    0

    Default Re: Rear disc brake conversion

    Quote Originally Posted by drakan1908 View Post
    ZJ disc brakes will work. You need to drill one hole and make the center hole in the backing plate slightly larger. A guy on our local forum did his , if I can find the write-up I'll post a link. Update...here is the link , pictures gone , starts at post 170
    http://www.vaoffroadsports.com/forum...ld-Blue/page17

    Sent from a van down by the river
    Awesome thank you

    Sent from my SAMSUNG-SM-J727A using Tapatalk

  5. #5
    abebehrmann's Avatar
    abebehrmann is offline Level: Uber Jeep Cherokee Trailer Queen
    Join Date
    May 2013
    Location
    Dallas, TX
    Posts
    6,597
    Chats
    2359

    Default Re: Rear disc brake conversion

    Download these extensions for Google Chrome or Firefox and the pics will show up for you.

    http://www.xjtalk.com/showthread.php?t=22646

  6. #6
    Join Date
    Jul 2017
    Location
    Clackamas, or
    Posts
    55
    Chats
    4

    Default Re: Rear disc brake conversion

    Rear disk brakes from a liberty are a direct swap since it came with a 8.25 with disk brakes from the factory.
    http://www.naxja.org/forum/showthread.php?t=977809
    http://www.xjtalk.com/showthread.php?t=4961
    Last edited by 89limited_hero; 09-28-2017 at 12:18 AM.

  7. #7
    Join Date
    Oct 2011
    Location
    S.E. Texas
    Posts
    29,250
    Chats
    1247

    Default Re: Rear disc brake conversion

    I've done the ZJ disc swap on my 92 with the 8.25 and it's fairly straight forward but more work than any of the write-ups say. And to be honest I would go a different route for mine. If you have plans to swap axles at some point or change gears think about getting a 8.8 that comes with discs, plus you can find them with 4.10 gears. The reason I say this is because I probably spent over 300 on the disc swap alone because of the donor parts needing new pads, rotors, and a few other pieces that added up. I do have a nice new setup but if you can find a donor with good pads, etc I would recommend it more because the cost would be much more appealing. The 8.8 axle swap could cost about the same and now you have better gears and a stronger setup out back. You would still need to change the front gears but once you add the amount you save on rear gears it makes sense. I just have to add that disclaimer now that I learn more, your choice of course.

    I went with the ZJ disc swap instead of the Liberty discs because my local junkyard had a dozen ZJs to choose from but only one Liberty that wasn't missing pieces so if you can find a Liberty donor I wouldn't hesitate to grab those. Only notable difference is you will need to open up the center hole of the ZJ rotors just a tad to fit onto the axle, whereas the Liberty is already set to it.

    Things you'll need to grab from the donor...
    -rotors
    -pads
    -backing plates/caliper brackets
    -calipers
    -soft brake lines
    -lug studs
    -ebrake cables (from a Liberty)

    A few things that usually don't make the write-ups.

    You'll need to re-bend your brake lines, however you're dealing with 17 year old lines that don't want to change shape so you may end up needing to bend up some new ones. This is easy if you've never done it.

    The soft brake hoses need a base to mount to where they connect to the hard line. This is to keep the constant movement from stressing the line and cracking it over time. I made a small bracket per side similar to a perch like for the leaf spring and welded it to the axle tube between the leaf spring and backing plate. If you don't want to/have access to weld I think you may be able to make a bracket to bolt to the shock mount, or sway bar mount if yours has one.

    Your jeep is a 97-01 meaning it's super easy to get the ebrake working again. You just need to grab a set of cables from a Liberty. They will work with either setup too.

    The lug studs need to be swapped out as well. The stock drum studs are too short to engage enough threads. You have a few options here. You can get the donor lug studs from either the ZJ or Liberty. I used the ZJ ones on mine. You can also use front XJ studs as well. If I did it again I would go with new XJ front studs just so everything matches and I could substitute one from the rear in case a few of the front broke, or vice versa.

    All in all its worth it, even having the added cost of replacing the maintenence parts I did. And if you want to keep the 8.25 and stock gears don't second guess it. I love not having drums anymore and don't ever want to go back. I don't daily drive mine but that's just because we have a 1 ton we drive for work. It's basically like it came from the factory like that.

    Hope this helps!




    Sent via messenger pigeon. I talk, he types.

  8. #8
    Join Date
    Sep 2017
    Location
    new york
    Posts
    26
    Chats
    0

    Default Re: Rear disc brake conversion

    Quote Originally Posted by XJ Wheeler View Post
    I've done the ZJ disc swap on my 92 with the 8.25 and it's fairly straight forward but more work than any of the write-ups say. And to be honest I would go a different route for mine. If you have plans to swap axles at some point or change gears think about getting a 8.8 that comes with discs, plus you can find them with 4.10 gears. The reason I say this is because I probably spent over 300 on the disc swap alone because of the donor parts needing new pads, rotors, and a few other pieces that added up. I do have a nice new setup but if you can find a donor with good pads, etc I would recommend it more because the cost would be much more appealing. The 8.8 axle swap could cost about the same and now you have better gears and a stronger setup out back. You would still need to change the front gears but once you add the amount you save on rear gears it makes sense. I just have to add that disclaimer now that I learn more, your choice of course.

    I went with the ZJ disc swap instead of the Liberty discs because my local junkyard had a dozen ZJs to choose from but only one Liberty that wasn't missing pieces so if you can find a Liberty donor I wouldn't hesitate to grab those. Only notable difference is you will need to open up the center hole of the ZJ rotors just a tad to fit onto the axle, whereas the Liberty is already set to it.

    Things you'll need to grab from the donor...
    -rotors
    -pads
    -backing plates/caliper brackets
    -calipers
    -soft brake lines
    -lug studs
    -ebrake cables (from a Liberty)

    A few things that usually don't make the write-ups.

    You'll need to re-bend your brake lines, however you're dealing with 17 year old lines that don't want to change shape so you may end up needing to bend up some new ones. This is easy if you've never done it.

    The soft brake hoses need a base to mount to where they connect to the hard line. This is to keep the constant movement from stressing the line and cracking it over time. I made a small bracket per side similar to a perch like for the leaf spring and welded it to the axle tube between the leaf spring and backing plate. If you don't want to/have access to weld I think you may be able to make a bracket to bolt to the shock mount, or sway bar mount if yours has one.

    Your jeep is a 97-01 meaning it's super easy to get the ebrake working again. You just need to grab a set of cables from a Liberty. They will work with either setup too.

    The lug studs need to be swapped out as well. The stock drum studs are too short to engage enough threads. You have a few options here. You can get the donor lug studs from either the ZJ or Liberty. I used the ZJ ones on mine. You can also use front XJ studs as well. If I did it again I would go with new XJ front studs just so everything matches and I could substitute one from the rear in case a few of the front broke, or vice versa.

    All in all its worth it, even having the added cost of replacing the maintenence parts I did. And if you want to keep the 8.25 and stock gears don't second guess it. I love not having drums anymore and don't ever want to go back. I don't daily drive mine but that's just because we have a 1 ton we drive for work. It's basically like it came from the factory like that.

    Hope this helps!




    Sent via messenger pigeon. I talk, he types.
    Thank you for all of the info!

    You said the 8.8 swap would be about the same price. And I've seen a few guys do it. What would be the pros/cons?

    Sent from my SAMSUNG-SM-J727A using Tapatalk

  9. #9
    Join Date
    Sep 2009
    Location
    Chico, CA
    Posts
    29,668
    Chats
    1838

    Default Re: Rear disc brake conversion

    Pros is a much stronger axle, unless you already have the 29 spline axles on the 8.25. Then you would gain some. Cons are that you need to weld in spring pads and get a U joint adapter for the pinion flange
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  10. #10
    Join Date
    Sep 2017
    Location
    new york
    Posts
    26
    Chats
    0

    Default Re: Rear disc brake conversion

    Quote Originally Posted by 4.3LXJ View Post
    Pros is a much stronger axle, unless you already have the 29 spline axles on the 8.25. Then you would gain some. Cons are that you need to weld in spring pads and get a U joint adapter for the pinion flange
    I'm not sure if I have 27 or 29 yet. Thank you for the info though!

    Sent from my SAMSUNG-SM-J727A using Tapatalk

  11. #11
    Join Date
    Jul 2017
    Location
    Clackamas, or
    Posts
    55
    Chats
    4

    Default Re: Rear disc brake conversion

    29 spline you have all 97+ xjs came stock in the 8.25. Unless for some crazy reason someone before swapped in an older 8.25 early 90's- some 96s. Were 27 spline.

  12. #12
    Join Date
    Sep 2017
    Location
    new york
    Posts
    26
    Chats
    0

    Default Re: Rear disc brake conversion

    Quote Originally Posted by 89limited_hero View Post
    29 spline you have all 97+ xjs came stock in the 8.25. Unless for some crazy reason someone before swapped in an older 8.25 early 90's- some 96s. Were 27 spline.
    That's great to know. Thank you!

    Sent from my SAMSUNG-SM-J727A using Tapatalk

  13. #13
    Join Date
    Oct 2011
    Location
    S.E. Texas
    Posts
    29,250
    Chats
    1247

    Default Re: Rear disc brake conversion

    Yeah, I forgot to mention the 8.8 does require welding. For that install you would need to weld on new spring perches and shock mounts, get a new yoke or adapter, new ubolts, possibly be able to use the ford ubolts plates, and depending on your wheel setup wheel spacers because the 8.8 is slightly narrower. Just got through doing this swap on my brothers '90.

    A quick rundown comes up right at 300. My local junkyard has rear axles for about 100. That varies greatly though and of course makes all the difference. But axle-100, ubolt-plates-perches-shock mount kit-140, yoke adapter-40. Just add some paint, welding wire, etc and you're done.

    Another possible plus if yours doesn't have the limited slip is some 8.8s did come with a lsd. It is harder to find a disc, 4:10, lsd axle though.

    Sent via messenger pigeon. I talk, he types.
    Last edited by XJ Wheeler; 09-29-2017 at 07:16 PM.

  14. #14
    Join Date
    Aug 2009
    Location
    Asheville, NC
    Posts
    7,955
    Chats
    39048

    Default Re: Rear disc brake conversion

    Can't wait to upgrade my rear brakes from drums... I just replaced all of the parts @ the wheels for the front and rear brakes, with the exception of the lines. And it stops far better than it did when I first got it.. but definitely not to where I feel it should be...
    FORMER GREEN XJ CLUB MEMBER
    IF YOU DON'T STAND BEHIND OUR TROOPS, FEEL FREE TO STAND IN FRONT OF THEM!!
    DOING SOMETHING JUST BECAUSE YOUR BUDDY DOES IT THAT WAY MAKES AS MUCH SENSE AS SHARING TOOTHBRUSHES

  15. #15
    denverd1's Avatar
    denverd1 is offline Level: Uber Jeep Cherokee Trailer Queen
    Join Date
    Dec 2011
    Location
    Tyler, Texas
    Posts
    5,729
    Chats
    1261

    Default Re: Rear disc brake conversion

    8.8 cons: swapping axles seems like a lot of work for marginally deeper gears and disc brakes. then you need gear set for the D30 and need to know how to setup gears. I wouldn't swap an axle to get disc brakes/4.10s.
    Wheelin' East Texas in a RED XJ

    RED 98 XJ with 4.5" lift, ZJ steering, front and rear locked on 33's
    cowl intake, Cobra CB, SYE, bumpers, 10K winch, lights
    ,___________
    //___l__,\____\,00_
    l_--- \___l---[]lllllll[]|
    (o)_)--(o)_)--(o)_)

Page 1 of 2 12 LastLast

Similar Threads

  1. XJ rear disc brake conversion ??
    By autotech98 in forum General Talk
    Replies: 15
    Last Post: 09-06-2014, 06:18 PM
  2. Disc brake change over
    By Jeepster19 in forum Wanted! (To buy)
    Replies: 1
    Last Post: 09-28-2012, 09:11 PM
  3. Replies: 16
    Last Post: 10-26-2010, 10:20 PM
  4. Disc break conversion
    By OrangeXJ in forum Modified
    Replies: 10
    Last Post: 08-31-2010, 04:06 AM
  5. Rear Disc Brake Upgrade
    By Jeepster19 in forum General Talk
    Replies: 5
    Last Post: 05-22-2009, 09:30 PM

Tags for this Thread

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •