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  #1  
Old August 18th, 2008, 10:08
toplessxj89 toplessxj89 is offline
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zj disc swap

i have searched and found a lot of usefull information on how to do the zj disc swap. i found a 1997 grand with the d44a with disc brakes at the local u pull it. i am going to pull the whole rear and remove the ebrake cables and cut the brake lines.

is there anything else i need to pull such as the master cylinder or any other braking components. i have a 1989 xj. and the brakes are going on a xj d44
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  #2  
Old August 18th, 2008, 10:28
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wolfpackjeeper wolfpackjeeper is offline
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Re: zj disc swap

v8 ZJ proportioning valve is a good call
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  #3  
Old August 18th, 2008, 13:30
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WheelinJR WheelinJR is offline
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Re: zj disc swap

I ran mine without the prop valve and it performed well. I had a 91, so I am not sure what year you're installing it on.

You need:
- Mount brackets
- dust shields (optional)
- inner e-brake assembly (optional)
- e-brake cables (optional)
- calipers
- rotors
- caliper soft lines
- pads and shoes

That said, I installed mine with no e-brake stuff at all, I got mount brackets, dust shields, soft lines, and calipers. Then I bought new rotors and pads, and that was it!

Personally I didn't want the ebrake. I eliminated the handle long ago and never used it anyways.
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  #4  
Old August 18th, 2008, 13:43
toplessxj89 toplessxj89 is offline
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Re: zj disc swap

what does that prop vavle do? i will probably just pull that too because they probably wont charge me any extra
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  #5  
Old August 18th, 2008, 13:46
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WheelinJR WheelinJR is offline
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Re: zj disc swap

Changes the proportioning of front to rear braking.

for example, you might have one now that is 70% front/30% rear and the ZJ one might be 60%/40%

I just threw #'s out, those aren't actual.
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  #6  
Old August 18th, 2008, 18:25
toplessxj89 toplessxj89 is offline
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Re: zj disc swap

o ok thanks.
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  #7  
Old August 25th, 2008, 15:15
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besthaticouldo besthaticouldo is offline
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Re: zj disc swap

will these install directly onto a stock 95 rear end?
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  #8  
Old August 25th, 2008, 19:17
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tomcat tomcat is offline
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Re: zj disc swap

Quote:
Originally Posted by toplessxj89
i have searched and found a lot of usefull information on how to do the zj disc swap. i found a 1997 grand with the d44a with disc brakes at the local u pull it. i am going to pull the whole rear and remove the ebrake cables and cut the brake lines.

is there anything else i need to pull such as the master cylinder or any other braking components. i have a 1989 xj. and the brakes are going on a xj d44
don't forget that you will have to re-drill the mounting holes on the backing plates and clearance the center axle hole for the bearing and seals, and will need a spacer on the outside of the seal to make up the differences in thickness of the backing plates. just finished mine yesterday
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  #9  
Old August 25th, 2008, 19:30
toplessxj89 toplessxj89 is offline
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Re: zj disc swap

i know that i had to clearance out the center axle hole but i thought the holes were the same on the d44. and i can get the spacer from the dealer correct?

i am still going to go ahead with it. drilling holes arent a big deal. i have a drill press i just have to measure twice drill once. its ussualy the other way around lol
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  #10  
Old August 25th, 2008, 19:45
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stewie stewie is offline
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Re: zj disc swap

Quote:
Originally Posted by besthaticouldo
will these install directly onto a stock 95 rear end?
they are a near bolt in on either a D35 or an Chrys 8.25. for these axles, you would have to slightly enlarge the center hole and elongate the holes for the bolts on the axle housing flange (grab those bolts too as they need to be slightly longer then the ones on our drum axles).

i installed zj brakes on my 01 XJ 8.25. the donor axle was a D44A.
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  #11  
Old August 25th, 2008, 19:53
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johnnyc johnnyc is offline
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Re: zj disc swap

Quote:
Originally Posted by besthaticouldo
will these install directly onto a stock 95 rear end?
If you want the parts, there were four rear disc-equipped ZJs sitting side-by-side in the Anaheim Pick-a-Part. And this coming weekend is 1/2 price.
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  #12  
Old August 25th, 2008, 20:55
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tomcat tomcat is offline
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Re: zj disc swap

Quote:
Originally Posted by toplessxj89
i know that i had to clearance out the center axle hole but i thought the holes were the same on the d44. and i can get the spacer from the dealer correct?

i am still going to go ahead with it. drilling holes arent a big deal. i have a drill press i just have to measure twice drill once. its ussualy the other way around lol
clamp it really well. lets just say i am on my second set, and a machine shop milled this set for me. you can get the axle flange with correct spacer built in, but that has to be drilled too. call up terraflex and see if they will sell you a set of spacers from their disk kit (they did for me). my axle was from an '89 MJ and they are the "old" pattern, vs the "new" pattern that the ZJ's are. terraflex lists the "new" kit as 91 and on.
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  #13  
Old August 26th, 2008, 10:10
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Daedalus454 Daedalus454 is offline
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Re: zj disc swap

Quote:
Originally Posted by tomcat
don't forget that you will have to re-drill the mounting holes on the backing plates and clearance the center axle hole for the bearing and seals, and will need a spacer on the outside of the seal to make up the differences in thickness of the backing plates. just finished mine yesterday
I'm trying to picture what you are talking about with the spacer. Do you have a non-c clip D35?
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  #14  
Old August 26th, 2008, 12:52
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tomcat tomcat is offline
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Re: zj disc swap

Quote:
Originally Posted by Daedalus454
I'm trying to picture what you are talking about with the spacer. Do you have a non-c clip D35?
nope, D44

read up:
http://pirate4x4.com/tech/billavista...kes/index.html
OP is putting brakes on a D44
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  #15  
Old August 26th, 2008, 16:15
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Daedalus454 Daedalus454 is offline
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Re: zj disc swap

Quote:
Originally Posted by tomcat
nope, D44

read up:
http://pirate4x4.com/tech/billavista...kes/index.html
OP is putting brakes on a D44
Gotcha, thanks!

I'm getting ready to do the swap on my 8.25", in my research I had not come across any mention of a spacer, but it makes sense that it would be needed in a non-c clip application.
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