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Dana 25 Front Disk Conversion for $250

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Nick_ View Drop Down
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    Posted: 06 Feb. 2017 at 10:22pm
Using your Jeep in the mud? Drums keep getting clogged with dirt? Front discs are the way to go. I purchased a conversion kit from a member here on my first restoration, and it works fantastic with the standard master cylinder and 9'' rear drums. No residual valves used. My next project is going the same route and I can't justify $700 parts suppliers are asking. 

How does $250 sound? 

Disclaimer: This includes the physical disc setup while using your original hubs, wheel bearings, and races. Other parts suppliers include these in the bundle, but most likely part, or all, are unnecessary. Brake lines are an additional cost.

By using this article as a reference, I have pieced together a complete front disk setup for a Dana 25 front axle. 

Do I need to grind my knuckles?
This is a great question. As outlined in the article: Once the brake pads wear down, the calipers will hit the knuckles and become useless. When installing my first conversion, I did not use instructions and therefore didn't grind mine down. I've traveled 1,000 miles without issue.  Brake pads on a lightweight CJ2A will take a long time to wear. However, I haven't physically looked at my caliper movement to see how close the clearance is. My Jeep is running a slightly different caliper bracket. You'll want to check this out and make the call - but I recommend safety first.

Calipers - $66
Chevy K10 4x4
O'Rreilly part #18-4124, 18-4125

Caliper Brackets - $90
1971-1978 Chevy 1/2 ton
Part #CB7191
Cheapest available here on eBay by seller vintagebrakesolutions about $30 less compared to all other suppliers. Hint: these brackets are the same ones used for 1966-1975 Ford Bronco disc conversions.

Brake Pads - $12
Chevy K10 4x4
O'Reillys part #LD52

Brake Rotors - $50
1977-78 CJ
BE CAREFUL: You want the 1 1/8'' rotors from 77-78, 1978+ used 7/8'' rotors.
Cost is discretionary depending on brand.
Part # Bendix PRT1155 for $50 on Summit Racing. 
Part #5109 Autozone, but $90. Good for reference in finding others by dimension.

Wheel Spacers - $11
5x5.5 bolt pattern, 1/4'' thick
You only need these if running the stock MB/CJ2A rim sizes. If using aftermarkets with offset, don't purchase. These are made of cast. I've been running these exact ones for over 1,000 miles on my Jeep and they work flawlessly. If you'd like aluminum you'll have to shop around.
Cheapest on eBay here by seller rdcobra91

Wheel Studs - $15
I have yet to purchase these, but you're probably going to need 1/2'' longer studs than stock (check exact measurements to be sure). Especially while using wheel spacers.

Total cost - $244
When purchasing parts: It may be cheaper to spend an extra few bucks from a single parts supplier and save on shipping. You can pick up the Autozone parts right at a local store, along with wheel studs. The caliper brackets and wheel spacers are more niche items. If my links on eBay have expired by the time you're reading this: Search around for an eBay deal.


Edited by Nick_ - 02 May 2017 at 3:29pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote cpt logger Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2017 at 4:54am
Nick, Thanks for this list.

I have a question. Does it matter if the Chevy disk parts are from a 2WD or a 4WD?

The reason I ask is I have a 1975 Chevy 1/2 ton 4X4 that I am parting out & my cousin has a 1974 Chevy 2WD that she is parting out. She would swap me if I needed her to. If both will work I will trade her out of her parts & keep mine as well. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote markcl52 Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2017 at 8:34am
great post. Do you know if this will work with the 15" wheels?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Nick_ Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2017 at 9:50am
cpt logger: Great question I'm not sure. If you find out while taking those apart, let me know.

Markcl52: Yes see above wheel spacers section.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2017 at 10:16am
Nick,

Disc Brakes are a great safety up grade.

I have done the Geo Tracker conversion on our trail Jeep (Dana 25).  No spacer are required.  I also put a dual master cylinder kit on at the same time (Herm's).  No grinding - stock Cj2A wheels fit.  Stops on a dine!  I love having disk brakes up front!

If people are using their CJ2A and not restoring it, it should be strongly considered.

Be Safe out there.

Stev


Edited by Stev - 07 Feb. 2017 at 10:23am
Stev
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bruce W Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2017 at 12:09pm
Cpt Logger,
  The 2WD does not have a separate caliper bracket, it is part of the spindle or knuckle. I'm pretty sure but not positive that the calipers and pads are the same, however.  BW
Happy Trails! Good-bye, Good Luck, and May the Good Lord Take a Likin' to You!

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Post Options Post Options   Thanks (0) Thanks(0)   Quote wheelie Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2017 at 8:25pm
Stev, got a parts list for the Geo set up?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Nick_ Quote  Post ReplyReply Direct Link To This Post Posted: 07 Feb. 2017 at 8:35pm
I'd be interested seeing that as well. Here is an excellent write-up on G503 but he states a 1/2'' spacer was needed.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 08 Feb. 2017 at 10:13am
Disk Brake Conversion for a Dana 25 using Geo Tracker parts:

Willys Stock CJ2A Wheel Disk Brake Conversion (combat rims would require a spacer to deal with the bolts in the combat rim).

This conversion is for a DANA 25 front axle.  It was done in conjunction with a dual master cylinder conversion.   The rear brakes remain as stock 9 inch drum brakes with 1 inch wheel cylinders.  A proportioning valve was used on this conversion. 

 

Parts required are from a Geo Tracker (1989 to 1998) L4 1.6L 1588cc two Door:

·         Calipers 2 each with mounting brackets

·         Rotors 2 each – solid non vented

·         Brake pads 

Tire bolts / studs (these are longer that the stock studs by 3/8 of an inch to accommodate the thickness of the brake disk):

·         Napa Part Number 641-1112

Metric bolts to mount the caliper mounting brackets to the backing plates:

·         Menards - HXCAP SW12MM-1.25X30MM M 2026862

·         Menards- HEX NUT 12mm 2026846

·         Menards- 3/8 “ Lock Washer 2326024

Spinal to steering knuckle bolts – These bolts are longer than stock because they have to capture the spindle and flat bracket that the caliper mounting brackets attach too.

·         Menards- HEX-CAP 3/8-24X1-1/4 GR 2028008 12each

Custom brake lines:

Ohio Hydraulics (2 each brake line assemblies) with these components:

·         1/8 SST Brake Hose Clear HFB09 (17” front and 12” Rear)

·         Banjo 10 x 10MM HFIF01

·         Female 3/8 x 24 19MM BQ251-SV

·         Braided Hoes Insert/Silver

Brake Line bolts:

·         Ohio Hydraulics (2 each) BQ1016 Banjo Bolt 10 x 1.0 x22mm

·         Ohio Hydraulics (2 each) BQ1016 H/D Copper washer 10mm

Bracket Conversion:

·         3/8 inch steel plate (2 each) flat stock to mount the calipers (I have a drawing and several sets of laser cut plates if you are serious about doing this conversion.  I can also send you a drawing if you need a pattern).



Ste








Edited by Stev - 08 Feb. 2017 at 10:19am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote smfulle Quote  Post ReplyReply Direct Link To This Post Posted: 08 Feb. 2017 at 2:49pm
I wonder what parts will be most available come time to replace stuff in 5-20 years? Just thinking out loud. Probably not going to do either.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Nick_ Quote  Post ReplyReply Direct Link To This Post Posted: 08 Feb. 2017 at 3:07pm
Chevy C10 parts will survive a nuclear fallout. They're everywhere.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 08 Feb. 2017 at 3:22pm
Stan, 

I have a couple of 70 year old Willys Jeeps that I can still find parts for on the internet.  I think you will be able to get what every you want in the future unless it is electronic.   None of these retrofits are irreversible.  This stuff just bolts on.  In the future if a better solution comes along just unbolt your old disc brake solution and install the new- fangled solution.  

Be Safe Out There.  

Stev


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Post Options Post Options   Thanks (0) Thanks(0)   Quote smfulle Quote  Post ReplyReply Direct Link To This Post Posted: 08 Feb. 2017 at 7:06pm
First off I want to thank Nick and Stev for their time and effort on this. I think it will be very helpful for many, maybe even me some day.

I work part time at a national brand parts store and it seems that the parts we stock and the parts we can order from the "warehouse" come and go as things age out. Things that don't move are dropped from in store stock, and eventually from special order stock.

Our jeeps are iconic vehicles and there will probably be a demand for spares for them for a long time, even though we often have to go to speciality vendor. Chevy stuff may or may not fall into that iconic future category. (Anybody out there putting any money into a Citation restoration?) It may just be me, but I think the Tracker is closer to the Citation than the Chevelle SS as far as likely to gain iconic status and therefore having spares produced well into the out years, in my opinion, is less likely. Not sure about the S-10, but there sure are a lot of them out there.

I'm not really making an argument here, just thinking out loud about stuff I might want to consider if I ever do this in the future.
Stan
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 08 Feb. 2017 at 10:24pm
Stan,

The Tracker is a bolt on solution that uses stock CJ2A rims.  No spacer.  What else have you got that can bolt up with no wheel spacer.  Let me know and we can figure out the backing plate.  The Tracker conversions backing plate is 3/8 piece of flat steel no bends, no special forgings, no stamping.  Just a pattern and bunch of holes.

I am all in on  whatever it takes to make these wonderful old machines actually stop reliably.  

They made 998,590 trackers - just under a million so there might be some parts out there for now.  How many CJ2As do you think are out there still in use?  A few thousand would be my guess.  Seems to be a lot of Trackers that could be scrapped for parts.

All good here just be safe out there.

Stev  


Edited by Stev - 08 Feb. 2017 at 10:26pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote rocnroll Quote  Post ReplyReply Direct Link To This Post Posted: 09 Feb. 2017 at 12:08am
OR....Stev can use his Tracker stuff, Stan can use his stock 9 inchers while he sells hundreds of Chevy parts and I'll keep using my Corvette four piston calipers all the while knowing that's not the route I would advise others to take.....and we all have brakes. Wink



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Post Options Post Options   Thanks (0) Thanks(0)   Quote berettajeep Quote  Post ReplyReply Direct Link To This Post Posted: 09 Feb. 2017 at 2:44am
Originally posted by smfulle smfulle wrote:

(Anybody out there putting any money into a Citation restoration?)


 Maybe if it is a X-11 LOL




 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote clayvt Quote  Post ReplyReply Direct Link To This Post Posted: 11 Mar. 2017 at 10:14am
I just ordered/picked up everything to do the chevy swap. Holy crap these calipers are huge!
I was able to get the calipers/hoses/pads and hardware kit all in stock at one of my local auto zones.
Rotors and studs from rock auto and the backing plates from the linked eBay seller

Excited to get everything in the mail and installed!

Question: I got the factory brake lines with the banjo bolt on the caliper. Is there going to be any issues using an adapter into my much smaller brake line? I don't remember the exact size I used but it's pretty much the smallest. The lines for these are massive...

Edited by clayvt - 11 Mar. 2017 at 10:19am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Lee (MN) Quote  Post ReplyReply Direct Link To This Post Posted: 11 Mar. 2017 at 11:00am
Originally posted by berettajeep berettajeep wrote:

Originally posted by smfulle smfulle wrote:

(Anybody out there putting any money into a Citation restoration?)


 Maybe if it is a X-11 LOL




 


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