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My front and rear Disc brake conversion

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 23 July 2021 at 1:17am
Next step was the wheel studs.  Oh those damn wheel studs.  I looked through every post I could find and tried each one of the wheel studs mentioned.  It seemed like none were a perfect fit.  Some had too high of a shoulder, some were too long, some were too short.  I ended up going to Dormans site and looking through their list of wheel studs narrowing down the fields to find the ones I needed.  I tried:
Dorman 610-036-1
Dorman 610-219
Dorman 610-106
Dorman 610-273
Dorman 610-449.1
Dorman 610-154

In the end, I ended up using Dorman 610-153.  Total with shipping from Ebay was $38.51 I did have to drill out the rotors to 5/8" but then all was right with the world.



I pressed out all the old studs from the front and rear hubs.



Then pressed in the new studs.  Here's a pic of me pressing in the rears... notice anything wrong here...?





Ok... here's a pic of me re-pressing in the new studs after I had to press them out because I put them in backwards.



I got the studs in the front hubs the correct way the first time at least!


43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 23 July 2021 at 1:18am
After spending way too long at the press... next step was the spacers.  I ordered 1" wheel spacers from Amazon for $90.72 shipped.



Here you can see that I think I found the perfect length wheel studs.  They just barely stick out (.03") from the spacer. 

43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 23 July 2021 at 1:21am
I used brakes lines from an 85 Honda Accord.  PN HB54010 for one side, I figured I'd get 2 for the left and 2 for the right so I ordered 2 for the other side PN  HB54011. (I can't remember which was which) I figured they'd be all the same length but the one side was WAY shorter than the other side.  I was going to exchange them, but I figured I'd just use the shorter ones on the rear axle since they didn't need to be as long as the front.  I actually am glad I did.  Less rubber hose to get snagged on junk.  Total with shipping for all 4 brake hoses was $20.87 from RockAuto.com  My local parts store wanted like 60 bucks for them!



The short brake hoses had these weird little studs sticking out from them, Anti-rotate pins maybe?  Who knows how those crazy Accords are designed!



 If I left them in, it'd be hard to get a socket on the caliper bolts so I cut them off.  Here you can see plenty of room for tools.



The front hoses had this "D" shape where it mounted to the frame.  I just took a file and filed in some corners to the circle and they fit perfectly.

43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 23 July 2021 at 1:26am
For the rear hose mounts, I had to make some brackets and welded them to the axle.





Here you can see the rear axle ready to go.




and the front axle




I also plumbed in the rest of the lines from the MC and the new proportioning valve.



43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 23 July 2021 at 1:28am
I bought one of those OEM tools one man brake bleeders for 3.99 at my local Fleet Farm.  it was super easy to bleed the brakes!  Worth every penny!  all 399 of them (well... plus tax)

I took it out today for a test drive to adjust the proportioning valve, and it was super easy to adjust.  Now my brakes are almost as good as my '03 TJ!  ...almost.

So the total "brake-down" for this project was:
4 - Brennan's brackets $110.00
2 - brake pads and rotor kits from a '94 Sidekick (Rock Auto #CRK4919) $159.91
4  - Calipers from '94 Sidekick (AutoZone #19B1212 & #19B1213) $183.80
4  - brake hoses from'85 Accord (Rock Auto #HB54010 & #HB54011) $20.87
20 - wheel studs from Ebay (Dorman 610-153) $38.51
4 - 1" Wheel spacers from Amazon (5X5.5") $90.72

Which brings my grand total for a front and rear disc brake conversion to $603.81

I upgraded to a dual reservoir master cylinder from KW (#376896) $374.00 but it wasn't absolutely necessary.

Considering that most disc brake conversion kits are around $800 per axle, I think I can afford it.  It was a lot of monkeying around, trying to find the correct parts and stuff, but that's part of the fun right!  I'm happy I did it, I've always wanted them and glad I have them now.  Especially since you can see the tires I normally have on this Jeep by the back bumper.




43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 23 July 2021 at 7:57am
Great Job!  You will really like having dependable brakes.  Thanks for sharing!

-Barry
1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 23 July 2021 at 8:51am
I see you had to drill the rotors - for the guys with stock Dana 25 hubs - if they use the Geo Tracker rotors they will fit over the wheel studs without the need for drilling out the holes.
Stev
1946 CJ2A Trail Jeep (The Saint), 1948 CJ2A Lefty Restored
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 23 July 2021 at 11:02am
Originally posted by Stev Stev wrote:

I see you had to drill the rotors - for the guys with stock Dana 25 hubs - if they use the Geo Tracker rotors they will fit over the wheel studs without the need for drilling out the holes.
Yeah, the only reason I had to drill them out was because of the shoulders on the wheel studs.  If the wheel studs were threaded all the way down, I wouldn't have had to drill them.
43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 23 July 2021 at 11:35am
FYI - NAPA has studs available that work without drilling.         Napa Part Number 641-1112



Stev
1946 CJ2A Trail Jeep (The Saint), 1948 CJ2A Lefty Restored
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Post Options Post Options   Thanks (0) Thanks(0)   Quote rocnroll Quote  Post ReplyReply Direct Link To This Post Posted: 23 July 2021 at 11:59am
This is doable without the spacers when using 16s, correct ?


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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 23 July 2021 at 3:10pm
Originally posted by Stev Stev wrote:

FYI - NAPA has studs available that work without drilling.         Napa Part Number 641-1112



The one I read about, but didn't try... figures.
43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 23 July 2021 at 3:12pm
Originally posted by rocnroll rocnroll wrote:

This is doable without the spacers when using 16s, correct ?


Not sure.  I didn't try any 16's.  My Terra tires are on 15's and I don't need them, but the skinny tires in these posts are on 15's and I need the spacers.  I've heard that some 16's need them and some don't.  I think I read somewhere that stock 16's do need them.  
43 GPW 93487 Blk
44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
48 CJ2A 156240 Red/Yel
48 CJ2A "Lefty" 181341 Red
61 CJ5 123120 Tan
03 TJ Inca Gld
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stev Quote  Post ReplyReply Direct Link To This Post Posted: 23 July 2021 at 10:41pm
Rocnroll -Yes, the Geo Tracker Disc Brake conversion will fit over stock CJ2A wheels.  Do a search for that thread or PM me and I can send you the build file I put together 5 or 6 years ago. 
Stev
1946 CJ2A Trail Jeep (The Saint), 1948 CJ2A Lefty Restored
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Post Options Post Options   Thanks (0) Thanks(0)   Quote wheelie Quote  Post ReplyReply Direct Link To This Post Posted: 24 July 2021 at 1:10am
Nice writeup. Thank you for taking the time.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Nick_ Quote  Post ReplyReply Direct Link To This Post Posted: 24 July 2021 at 9:05am
Out of curiosity, how is your braking power? I found the pedal kept hitting the master lid, and only got about 1/3  required pedal travel. A few days ago I spaced my setup 2.5" forward and it more than doubled stopping power. Another of hacking was required.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote rocnroll Quote  Post ReplyReply Direct Link To This Post Posted: 24 July 2021 at 9:44am
Originally posted by Stev Stev wrote:

Rocnroll -Do a search for that thread or PM me and I can send you the build file I put together 5 or 6 years ago. 

I remembered your thread but just couldn't remember about the wheels....just a question for the conversation. Not actually ready to do the conversion but will at a later date for sure....starting to collect parts so it won't hit me all at once.

Your thread will be very helpful especially with the parts shopping.

Thanks! Thumbs Up
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'48 CJ2A Lefty

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Post Options Post Options   Thanks (0) Thanks(0)   Quote rocnroll Quote  Post ReplyReply Direct Link To This Post Posted: 22 Mar. 2023 at 6:15pm
Originally posted by Stev Stev wrote:

FYI - NAPA has studs available that work without drilling.         Napa Part Number 641-1112




Stev, my friendly old time counterman crossed that NAPA number to a Dorman 610-080.

Supposed to be the same stud if you want to add that to your file.



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Post Options Post Options   Thanks (0) Thanks(0)   Quote dasvis Quote  Post ReplyReply Direct Link To This Post Posted: 12 Dec. 2023 at 2:50pm
I just did the Brennan's bracket Geo Tracker disc conversion on my CJ3A. Used Dorman 610-034 wheel studs, just had to kiss the rotor stud holes with a 1/2" drill bit & everything bolted together like it was made that way. No issue with stud length or my stock 16" Willys wheels at all.
  Ninja disc brakes!
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1953 CJ3A #453-GB1 11266 "Black Beauty"
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..... & one of them moves under it's own power!!
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