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  #31  
Old September 19th, 2008, 07:31
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mjma mjma is offline
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Re: XJ Dana 44 Ford Explorer Disc Conversion

Quote:
Originally Posted by xcm View Post
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
Nice Truss!! I want!! My D44 looks kinda small with my Q78 (36") tires!

Wait a minute....where are your shocks??
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  #32  
Old September 19th, 2008, 20:46
xcm xcm is offline
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Re: XJ Dana 44 Ford Explorer Disc Conversion

not installed in that pic, i ended up welding em up on the truss
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  #33  
Old September 27th, 2008, 15:08
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hot_rod_hooligans hot_rod_hooligans is offline
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Re: XJ Dana 44 Ford Explorer Disc Conversion

markw, did you set yor calipers leading or trailing? as I'm getting ready to bolt everything together, it looks like they fit perfect trailing, but can't remeber for the life of me if they lead or trailed on the exploder I pulled them off of. They'll require a little shaving off of the flange on the axle tube to lead.
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  #34  
Old September 27th, 2008, 18:30
downhillracer downhillracer is offline
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Re: XJ Dana 44 Ford Explorer Disc Conversion

They trail... I just did this swap yesterday. Everything went together just like this write up said it would. I have yet to get the axle under the jeep yet so I cant comment on the stopping power increase. Looks cool though.
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  #35  
Old September 27th, 2008, 19:10
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hot_rod_hooligans hot_rod_hooligans is offline
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Re: XJ Dana 44 Ford Explorer Disc Conversion

Cool thanks, just have to get the calipers and get the rotors machined, and I'll have my brakes done. The axle still needs new axle seals and bearings, a new pinion seal, brake lines(hard and soft), and it will be ready to go in.
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  #36  
Old September 27th, 2008, 20:12
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markw markw is offline
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Re: XJ Dana 44 Ford Explorer Disc Conversion

They trail. I'm going to do mine this weekend. Tom's setup is working fine.

Here's the "after"



One thing I did was take ultragrey RTV and use a couple of dabs on that to center the preload ring on the axle seal (basically glued it). I let that set up before putting the axles in so I didn't have to putz around making sure that ring wasn't riding on the axle shaft. It's something to watch out for.

Oh, and the drivers side brakeline got moved up about an inch from this picture.
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  #37  
Old October 2nd, 2008, 05:58
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Re: XJ Dana 44 Ford Explorer Disc Conversion

Did anyone have any problems using the factory knurled bolts on the housing that hold the bracket/shaft on? Are longer ones needed?

EDIT: Oh and what about wheel studs? Are factory ones long enough?
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  #38  
Old October 2nd, 2008, 07:40
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IllianaXJ IllianaXJ is offline
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Re: XJ Dana 44 Ford Explorer Disc Conversion

On my 8.8 I reused the stock ebrake cables, cut the spring and used a cable clamp. Didn't mess with a thimble, not enough room to get one in. It's been holding up great for a year or so now.
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  #39  
Old October 2nd, 2008, 21:41
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Re: XJ Dana 44 Ford Explorer Disc Conversion Howto

Quote:
Originally Posted by mark1 View Post
....Give neighbor a beer and have him machine the center of the explorer rotors to fit over D44 axle shafts....
Or use zj rotors which are usually cheaper than explorer rotors and don't need the center hole enlarged.

Got that bit from Jsolorza "Jose".

Nice write up Mark.
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  #40  
Old October 4th, 2008, 21:37
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Re: XJ Dana 44 Ford Explorer Disc Conversion Howto

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Originally Posted by corbinafly View Post
Or use zj rotors which are usually cheaper than explorer rotors and don't need the center hole enlarged.

Got that bit from Jsolorza "Jose".

Nice write up Mark.
Yeah, I may be going that way. The ZJ looks like it will sit further inboard, and the rotor is slightly thinner. I've got the outer pad dragging on the Ford rotor. I'll pick up some ZJ parts tomorrow.

Here's the specs from CSK's site with the Raybestos.

Ford Rotor

Rotor Specifications:

* Type: Rotor - w/ Parking Brake Drum in Hat
* Number of Bolts/Holes: 5
* Bolt Circle Dimension: 4.5"
* Discard Thickness: .433"
* New Surface Thickness: .473"
* Outside Diameter: 11.22"
* Overall Height: 2.295"

ZJ
Rotor Specifications:

* Type: Rotor - w/ Parking Brake Drum in Hat
* Number of Bolts/Holes: 5
* Bolt Circle Dimension: 4.5"
* Discard Thickness: .374"
* New Surface Thickness: .43"
* Outside Diameter: 11.22"
* Overall Height: 2.33"
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  #41  
Old October 5th, 2008, 10:14
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Re: XJ Dana 44 Ford Explorer Disc Conversion

Ok, just threw some ZJ rotors on. They move the rotor inboard about 1/8" and seem to fit way better. I was having the outer pad on my drivers rear drag and build up heat on my test drive. Just wanted to pass this info along FYI. Oh, yeah, you don't have to do anything to the ZJ rotor, it just goes right on, no turning on a lathe.
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  #42  
Old October 24th, 2008, 14:35
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Re: XJ Dana 44 Ford Explorer Disc Conversion

Damn, I really wish I would have read this about a week and a half ago.... guess I'm stuck with Explorer rotors for now.
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  #43  
Old October 24th, 2008, 17:21
xcm xcm is offline
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Re: XJ Dana 44 Ford Explorer Disc Conversion

Quote:
Originally Posted by MoparManiac View Post
Did anyone have any problems using the factory knurled bolts on the housing that hold the bracket/shaft on? Are longer ones needed?

EDIT: Oh and what about wheel studs? Are factory ones long enough?
the four bolts that hold the axle + bracket + axle housing together dont need to be messed with!

ive heard conflicting things about the wheel studs.... however i run one with extended GC wheel studs, and 1 with alloy shafts + just the regular wheel studs that come with the shafts... the extended gc's are a bit longer, however im comfortable with the ammount of thread engagement on the stock sized studs, and nothing has broken wheel stud wise on either axle!
if i start breaking wheel studs, naxja will be the first to know about it.
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  #44  
Old October 25th, 2008, 22:41
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Re: XJ Dana 44 Ford Explorer Disc Conversion

Just a FYI on OEM Jeep wheels that work and wheels that do not regarding caliper clearance. The stock Ravines DO, the Canyons DON'T.
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  #45  
Old October 26th, 2008, 00:12
VegasAnthony VegasAnthony is offline
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Re: XJ Dana 44 Ford Explorer Disc Conversion

Quote:
Originally Posted by MoparManiac View Post
Did anyone have any problems using the factory knurled bolts on the housing that hold the bracket/shaft on? Are longer ones needed?

EDIT: Oh and what about wheel studs? Are factory ones long enough?
Yes they were toast so I took em out and got all new grade 8 bolts and nuts and grinded one side of the head flat

fukin wheel studs , what a pain in the ass.....

stock will not work and try and to find the same knurl in a .5 to1" longer stud..I went a tad higher and they woulndt seat right

I ended up welding the fukers to the axle
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