Disc Brake Conversion

Carl McFly · Unread post by **Carl McFly** » Mon Apr 02, 2012 8:38 pm

Chris, it's your if you want it. Has upper and lower control arms and a track bar on it, but that's about it. I just need to get one more stud out of one axle tube. I had good luck, I have seven pounded out. But there's one that just.... won't....... quit. I call it Rick Santorum

nostaw · Unread post by **nostaw** » Tue Apr 03, 2012 9:39 am

Little Napoleon wrote:
Carl McFly wrote:that's true..... unless I got a good deal on a diff, because it had no axles
let me know if you don't want the tube when your done...

Am curious... What do you want it for?

JW

ChrisD · Unread post by **ChrisD** » Tue Apr 03, 2012 10:25 am

Get in line Jon..

johnsxj · Unread post by **johnsxj** » Tue Apr 03, 2012 10:50 am

Not to discourage Carl from getting rid of stuff but.....

Just as an FYI the aluminum center section D44's out the Grands use differential parts that aren't quite the same as regular D44's (they're a C-clip axle!)
You can get gears up to 4.56 but there's nothing for traction aids except for the stock limited grip.

ChrisD · Unread post by **ChrisD** » Tue Apr 03, 2012 12:16 pm

From the photos, I didn't think this was an aluminum center section...

nostaw · Unread post by **nostaw** » Tue Apr 03, 2012 3:31 pm

Little Napoleon wrote:From the photos, I didn't think this was an aluminum center section...

That is why I was asking. All ZJ D44 are aluminum center sections and aren't well supported by the after-market.

JW

ZAEDOCK · Unread post by **ZAEDOCK** » Tue Apr 03, 2012 4:21 pm

I would cut it in half and use it to make a hole auger.

ChrisD · Unread post by **ChrisD** » Tue Apr 03, 2012 4:28 pm

I don't recall Carl stating what the axle is out of...

DOUG · Unread post by **DOUG** » Tue Apr 03, 2012 6:02 pm

Little Napoleon wrote:I don't recall Carl stating what the axle is out of...

From Carls Ad in the for sale forum...

Carl McFly wrote:I might be picking up a rear D44 this weekend, from a Grand Cherokee (ZJ). Once I get done with it, if anyone's interested in the carcass, let me know. It's from a '96, with the you-gotta-have-em 3.73 gears. Bottom line? You're looking at a D44 diff with gears and tubes. And that's about it. If nobody claims it, it's going to my neighbor, who collects scrap metal for recycling

Carl McFly · Unread post by **Carl McFly** » Sat Apr 14, 2012 11:40 pm

Quick update on the conversion
(look for a complete write up in Tracks with lots of pics and details... hopefully the May edition)

Glad I'm taking it slow and double checking everything, there were a few gotchas waiting for me! Like the mounting bracket for the rear brake hoses. My 44 doesn't have them

So I cut them off my donor axle, and once the new brake line's on there, I'll see exactly where to weld them onto my spring perch

Looks like when I'm done, I'll be into this for maybe $350 - $400. Not a lot less than some of the kits out there, but this includes a LOT of stuff. New rotors, calipers, brake pads, e-brake shoes, rear brake lines and flex hoses, and e-brake hardware

Started picking up the new parts today, my plan is to pull the trigger on this next Saturday. I hope

nostaw · Unread post by **nostaw** » Sun Apr 15, 2012 9:33 am

Carl -

Do you remember the brackets I made to hold the disc brake soft lines?

Bet you can do the same... The angle I used came from Home Depot...

JW

Carl McFly · Unread post by **Carl McFly** » Tue Apr 17, 2012 8:55 pm

Thanks Jon, but the pieces I cut off the donor axle *should* line up with my spring perch's. My plan is to run a little bead weld and make them one with my 44. Also, I picked up all the pahts I need, except the calipers. Today, I got a new jug of Anti Seize and tube of LockTite so even the little things on my list are covered. One more trip to the pahts store for fresh calipers, and I'm ready to light this candle

AND the latest forecast has the weather cooperating on Saturday!!

Carl McFly · Unread post by **Carl McFly** » Tue Apr 24, 2012 7:23 pm

After a productive day Saturday (that was unfortunately cut short), my work schedule cooperated today and I was able to run the second brake line on the axle, and hook up my e-brake cables. Next up, install the second caliper and brake hoses. Uh-huh........ Soooo, how did that go?

Thanks to Auto Zone

, not real well. The passenger side caliper was bolted on Saturday, and looked shiny and purty. Went to bolt on the drivers side today and when I try to put on my pads..... lets just say the inboard pad had lots of play

And the HW that secures the caliper was the wrong length. I could live with the different size of the bolt head but they were also about .125" shorter than they should be. And while I may not agree with everything the Jeep engineers do, I'm going to trust their judgement on this

But I can still get the other side bolted up, right? Well I could, if the banjo bolt that secured the brake hose would thread into the caliper. So both calipers are going back and I'm picking up replacements tomorrow. And I'm hoping the weather holds out AND my work schedule allows it, so I can get this system buttoned up before the weekend and the J-101

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