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  #16  
Old September 18th, 2008, 14:27
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Re: XJ Dana 44 Ford Explorer Disc Conversion

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Originally Posted by markw View Post
Looks purty. Did you regear?
No, not yet, I'm waiting to regear till I bump up my lift to 4.5" and to 33"s, because I want to got to 4.88's, and with 31"s that be a screamer. I'll throw an ARB in there with the new gears, but that may not be till next summer.

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Originally Posted by mjma View Post
But basically, mine looked like the above when I got it home from the junkyard, and when it was finished it looked shiny, but not as shiny as the above!!
What do you mean shinny? Thats flat black paint! Thanks for the complement though. It was about my only choice though, a wire wheel wasn't cutting it so I hit it with the grinder, and ended up grinding most of it smooth getting the rust off, everything else is just because I'm a little talented with a paint can.
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  #17  
Old September 18th, 2008, 14:34
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Re: XJ Dana 44 Ford Explorer Disc Conversion

Great write-up, Mark.

Subscribed for future reference.

I know you got your brakes from a '95. Do you know the range of years that would work?
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  #18  
Old September 18th, 2008, 14:47
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Re: XJ Dana 44 Ford Explorer Disc Conversion

95/96 had dual master cylinder which is a bolt in swap, and the first thing I did when I bought mine. Mine will be converted to disc next week, I've got a ZJ prop valve so I'm going to use that combined with the XJ valve and see how it works. Worse case is I'll put a wilwood adjustable prop valve in the rear line. Disc brake and the nationals are what's left on my Moab list.
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  #19  
Old September 18th, 2008, 15:07
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Re: XJ Dana 44 Ford Explorer Disc Conversion

I know different people have said different things about this, but when I put my crown vic discs on the D44 in my 96 XJ, everything worked out fine. I can lock all 4 tires up. I didn't touch the proportioning valve, and the braking seems perfect to me.
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  #20  
Old September 18th, 2008, 15:08
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Re: XJ Dana 44 Ford Explorer Disc Conversion

anyone having trouble with enlarging holes in backing plates.... visit mcmaster carr's website, and buy a 'rotary burr'.... these are the 'GOOD SHIT', and cut thru steel like butter, HOWEVER, they make shard-shaped burrs.... and these are killer, and will stay in the area of your garage near the drill press for at least a couple months... thats the only downside, but it sure beats a crapload of home depot bits..

three things,
1- aftermarket wheels are a must, at least for crown vic brakes, the stock wheels dont clear the caliper
2- cv's are very, very common in the yards, TONS of wrecked taxis.. explorers are a bit more scarce, allthough hardly rare... WAIT for a 50% off weekend!
3- im on my 2nd d44, and both have had issues with axle seals, both are due to me being inexperienced with axle work, but the lesson is, use rtv on the axle seals when dropping in the axleshafts...


ANYTHING BEATS GREEN AND GOLD! the gear guy was feeling frisky!

after new paint

Last edited by xcm; September 18th, 2008 at 15:21. Reason: edit: eye candy
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  #21  
Old September 18th, 2008, 15:09
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Re: XJ Dana 44 Ford Explorer Disc Conversion

Yeah, I'm going to try it stock first, the if need be start playing with prop valves.

XCM:

That's basically what I did, we have "Pat's Tools" in El Cajon, $10-$20 for rotary burrs and they last forever. Did 4 backing plates, 2 Durango steering box piston cover stops, and numerous other jobs with it.
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  #22  
Old September 18th, 2008, 15:17
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Re: XJ Dana 44 Ford Explorer Disc Conversion

I've run both stock aluminum 'grizzly' wheels with the crown vic discs and some aluminum ford ranger wheels (which also require having the center grinded out!). I just used a cheap-o black and decker dremel.
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  #23  
Old September 18th, 2008, 16:52
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Re: XJ Dana 44 Ford Explorer Disc Conversion

neither the 5 spokes, nor the 11 spoke alloys from the 1990 era fit on my crown vic setup... just trying to warn of potential issues, my bad if some wheels WILL fit... better safe than sorry
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  #24  
Old September 18th, 2008, 17:09
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Re: XJ Dana 44 Ford Explorer Disc Conversion

Anyone know if the American Racing D windows work unmodified?
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  #25  
Old September 18th, 2008, 17:12
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Re: XJ Dana 44 Ford Explorer Disc Conversion

I think those are the wheels I've got with 4.5" backspace. I'm going to find out soon.
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  #26  
Old September 18th, 2008, 17:26
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Re: XJ Dana 44 Ford Explorer Disc Conversion

Quote:
Originally Posted by hot_rod_hooligans View Post
Anyone know if the American Racing D windows work unmodified?
not specifically, BUT the AR mohaves DO.... maybe you can compare the BS of both of those, and go from there. Should you get stuck with wheels that dont fit, you can allways pickup some wheel spacers like i did
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  #27  
Old September 18th, 2008, 19:23
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Re: XJ Dana 44 Ford Explorer Disc Conversion

They're 15"x8"s with 4"bs, They already stick out like crazy since I've already removed the fender flares, add wheel spacers onto what I already have is gonna be crazy looking.
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  #28  
Old September 18th, 2008, 19:35
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Re: XJ Dana 44 Ford Explorer Disc Conversion

few years ago I ordered an Explorer disk kit from gef racing
It is a little over $300 for all new emerg brake/backing plate/dust shields,calipers, pads, spacers, hardware. ( no brake lines). The install was exactly as you detailed, and it was nice to have all new parts and spacers included
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  #29  
Old September 18th, 2008, 19:47
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Re: XJ Dana 44 Ford Explorer Disc Conversion

That price beats others(tera-flex for one--did yall see how much quadratec was asking in the latest catalog?) by half! That is the no brainer kit for those that don't want to piece it together or/and hit up the JY.
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  #30  
Old September 18th, 2008, 20:34
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Re: XJ Dana 44 Ford Explorer Disc Conversion

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Originally Posted by hot_rod_hooligans View Post
They're 15"x8"s with 4"bs, They already stick out like crazy since I've already removed the fender flares, add wheel spacers onto what I already have is gonna be crazy looking.
sounds like you should be fine!
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