Issue with ZJ disc to 44 swap

OverlandZJ · Nov 15, 2013

I'm installing the XJ D44 into the ZJ and attempting to swap the ZJ disc's over.(Previously had TSM discs)

I have the caliper brackets redrilled, center hole enlarged, Teraflex spacer installed under OEM XJ44 retaining plate. Axleshafts installed into housing.

Heres where it gets interesting.. my rotors wont seat flush on the axleshaft flange. The rotor does fit over the wheel stud "shoulder" but stops short of seating correctly, it appears to be the slight "step" on the hub? of axleshaft just before the mating flange.

Yesterday I enlarged the center hole on one rotor like I did with the brackets, and got it to sit flush. But in my searching i'm finding no one else who reports this.

Did you swap ZJ discs to your 44? Did you experience this issue?

NW-ZJ-SCOTT · Nov 15, 2013

I've never heard of someone having to wallow out a rotor??

Hmm

blondejoncherokee · Nov 15, 2013

post pics. No one has ever had to do that. Do you have the right rotors? Are you installing this thing wrong? Ive done the swap its easy and straight forward.

OverlandZJ · Nov 15, 2013

NW-ZJ-SCOTT said:
I've never heard of someone having to wallow out a rotor??

Hmm

Neither have I Scott. I fear i'll end up being shown for the idiot I can be at times..

blondejoncherokee said:
post pics. No one has ever had to do that. Do you have the right rotors? Are you installing this thing wrong? Ive done the swap its easy and straight forward.

My camera just took a dump the other day. I could take and post latest pics tonight.. this link shows my build up to the point of trying to fit the rotors.. including the work on caliper bracket.

http://www.naxja.org/forum/showthread.php?t=1061371&page=20

All parts are coming from the ZJ D35 I pulled from my rig.

I'd love for someone to point out what i'm doing wrong here.

SuperRA · Nov 15, 2013

I too don't recall having to modify the rotors when putting ZJ brakes on my D44.

techno1154 · Nov 15, 2013

OverlandZJ said:
I'm installing the XJ D44 into the ZJ and attempting to swap the ZJ disc's over.(Previously had TSM discs)

I have the caliper brackets redrilled, center hole enlarged, Teraflex spacer installed under OEM XJ44 retaining plate. Axleshafts installed into housing.

Heres where it gets interesting.. my rotors wont seat flush on the axleshaft flange. The rotor does fit over the wheel stud "shoulder" but stops short of seating correctly, it appears to be the slight "step" on the hub? of axleshaft just before the mating flange.

Yesterday I enlarged the center hole on one rotor like I did with the brackets, and got it to sit flush. But in my searching i'm finding no one else who reports this.

Did you swap ZJ discs to your 44? Did you experience this issue?

Funny! Now that you mentioned that, I had to enlarge the center holes in the rotors on my XJ also. Even funnier is the fact that I have not seen it mentioned on the forums I have visited prior to doing the conversion.

To keep every thing simple for me, I got from a Pick-A-Part in Miami all the break parts from a 1996 ZJ with the Laredo package to match my XJ year of 1996. I followed all other instructions I found and did the modifications and installation with never a problem,...that is until I tried to put the rotors on. The entire hole was opened up to maybe less that 1/8 inch total. Nothing that a dremel could not handle.

eflores · Nov 15, 2013

i had to wallow out my rotors ever so slightly....mine did the same thing
30 seconds with a sanding drum and all was right in the disc brake 44 world again

XJEEPER · Nov 16, 2013

I used TJ rotors on my D44 and the rotors slid right on, which makes sense because it was a D44 disc to D44 , not a D35 disc to D44 swap.

ADVNTURR · Nov 16, 2013

I ran into the same problem when I put ZJ discs on my XJ D44. I chose to (because I had access to a large lathe) turn down the hub on the axle shaft to match the rotor so that in the future I didn't have to modify the next set of rotors.

Redxj5150 · Nov 16, 2013

Are all of these just with stock 44 axle shafts or does anyone have this problem with alloys from any manufacturer?

XJEEPER · Nov 16, 2013

Red, I'm running alloy shafts.....NP.

OverlandZJ · Nov 16, 2013

OK now I feel better about the issue seeing where others also had to clearance.

I opened one rotor up like I did the caliper brackets.. square from front to back. I now see that I could have just deepened the taper on the backside and been ok.

Appreciate the input...

techno1154 · Nov 16, 2013

Redxj5150 said:
Are all of these just with stock 44 axle shafts or does anyone have this problem with alloys from any manufacturer?

Mine is all stock. Came from a 1986 or 1987 (I do not remember) Wagoneer.

XJEEPER said:
I used TJ rotors on my D44 and the rotors slid right on, which makes sense because it was a D44 disc to D44 , not a D35 disc to D44 swap.

Are those TJ rotors bolt spacing 5 X 5.5" or 5 X 4.5" like the XJ?

XJEEPER · Nov 17, 2013

TJ is the same as XJ, JK is 5x5

Here's a nice guide for swappers..... http://www.jeep4x4center.com/knowledge-base/jeep-wheel-specifications.htm

kastein · Nov 17, 2013

I wouldn't want to open out the center hole with anything other than a lathe, seeing as that's what actually locates the rotor. But I'm weird like that, I either don't care at all about something or it has to be absolutely perfect.

DanMan2k06 · Nov 17, 2013

I had to do the same. Used zj centric premium rotors, and they were a hair too small. Used a cylinder hone that i temprarily glued some 400grit sandpaper to the abrasice blocks. Worked great, no issues.

Issue with ZJ disc to 44 swap

OverlandZJ

NAXJA Member # 101

NW-ZJ-SCOTT

TEXAS-JT-SCOTT

blondejoncherokee

NAXJA Member

OverlandZJ

NAXJA Member # 101

SuperRA

NAXJA Forum User

techno1154

NAXJA Member

eflores

NAXJA Forum User

XJEEPER

NAXJA Member # 13

ADVNTURR

I worry when rattles stop

Redxj5150

NAXJA Forum User

XJEEPER

NAXJA Member # 13

OverlandZJ

NAXJA Member # 101

techno1154

NAXJA Member

XJEEPER

NAXJA Member # 13

kastein

NAXJA Member

DanMan2k06

NAXJA Forum User

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