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My front and rear Disc brake conversion

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    Posted: 03 July 2021 at 1:10am
My trailrider is a '65 CJ5 with a 2A body tub on it.  It is the definition of "salad Jeep".  I haven't really driven it for a year and when I did this year, the brake pedal went all the way to the floor, and the plunger on the master cylinder got stuck in. At first I was thinking I'd just rebuild or replace the stock master cylinder, but I thought that the wheel cylinders might also be stuck so I figured I'd go with one of those dual reservoir master cylinders from Kaiser Willys. I run 31" Terra tires on it and I've always wanted an excuse to do a disc brake conversion, so I figured now was the perfect time, and why not do a front and rear conversion while I'm at it.

I did my research, ordered my parts, and most of them came in today so I thought I'd get started.  Let me take you along for the ride.  I'll try to keep as many details and prices as I can.

I decided to go with the Tracker/Sidekick conversion, or as many are calling it the "Trackkick" conversion I guess. I ordered the brackets from Brennan's Garage.  I got four of them.  Total was 110.00 shipped.

I ordered the dual reservoir master cylinder kit with included proportioning valve (item #376896) from KW. Total was 374.00 shipped.

I ordered 2 "rotor and brake pad kits" for a 1994 Suzuki Sidekick from Rock Auto, (part number CRK4919)
Which came with POWER STOP (17418) brake pads, and POWER STOP (JBR564EVC) rotors.
This is enough for 2 complete front axles.  Total from Rock Auto was 159.91 shipped.

I also ordered 4 calipers with brackets for a 1994 Suzuki Sidekick 2 front left and 2 front right (part numbers 19B1212 and 19B1213) from my local O'Reilly Auto Parts.  I would have got them from Rock Auto also, but Rock Auto said the core needed to be from the same vehicle.  O'Reilly said I could put whatever I wanted into the box as long as they were calipers.  My brother in law is junking a 2000 Allero with four wheel disc brakes, so I took the calipers and brackets off of that, and used them as cores. Total I paid with tax, for the four calipers (and once I got my 120.00 core charges back) was 183.80

So I started with 4 jack stands and pulled off all the tires.  


Then starting with the front  Dana 27 axle, I removed the front hubs...


spindle nuts and washers....



Then the drum brake backing plates along with the rubber brake hoses, leaving it ready for Brennan's brackets.







Edited by Scratch - 03 July 2021 at 1:31am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 03 July 2021 at 1:14am
Then I moved onto the rear Dana 44 axle by pulling the drums off...





And using a lady slipper pry bar to remove the wheel hub dust cover...  






Then removed the cotter pin, and castle nut brackets.




Next I used a 3 jaw gear puller to pull the hub.  I had to get plenty of pressure on the gear puller, then with a bit  of "persuasion" with a Jeep wrench, the hub popped off. 




I then pulled the drum brake backing plates off and the rear axle was ready for Brennan's brakcets.





Edited by Scratch - 03 July 2021 at 1:34pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 03 July 2021 at 1:15am
Per Brennans website, he says: 

-My conversion bracket goes OVER the spindle just like the stock drum brake backing plate did. In a rear D41/44 application with 2pc axles the my bracket goes between the bearing retainer and dust shield.  

Here is a picture of the rear axle and along with it, my first question.  There are four "plates" on each side.  The back two are what I assume to be shims.  The furthest one in is thin, and the next one is much thicker.  Then there is a "seal type" plate, and finally a "dust cover" type plate. ( I'm not sure on terminology) The two I'm holding were on the outside of the drum brake backing plate.  I wasn't sure where to put the bracket so I put the two shims, and the first seal on, then the caliper bracket, and finally the dust cover.  I did it this way because that seemed to center the rotor on the caliper nicely.  Does that sound correct?






Edited by Scratch - 03 July 2021 at 9:23pm
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For my second question, if you notice on the "dust cover" above, there is a raised hump, but I can't remember where that was supposed to go.  On the top, on the bottom... does anyone know?  I see an extra hole in each of the other plates, is that supposed to line up with the hump, and if so, where do I clock it to?



Edited by Scratch - 03 July 2021 at 1:21am
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46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
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Next you can see all the parts that I removed and will not be re-installing.


In this next picture, you can see all of the new replacement parts that need to go in.  A not so keen eye will notice that one of the calipers is not shiny silver like the rest.  It is identical except for the color.  I'm not very OCD so I'm not going to worry about it.



Edited by Scratch - 03 July 2021 at 1:29am
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44 GPW 230283 OD
46 CJ2A 50100 Tan
46 CJ2A 77632 Wht
47 CJ2A 141681 Grn
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 03 July 2021 at 1:22am
In the next picture you can see I've mounted the caliper bracket, then re-installed the hub, castle nut, cotter pin and wheel hub dust cover.  




The rotors did not need to be drilled out for my lug studs, and were a very tight fit, but the rear studs had a bit of a shoulder on them...




So I drilled the back of the rotors a little bit so the shoulder would clear it.



Edited by Scratch - 03 July 2021 at 1:31am
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My next questions have to deal with the brake pads. Since I don't have a Suzuki Sidekick here for reference, which way do the brake pads go? With the little metal extension piece on the top or the bottom?  Does it matter?  What is that little piece?  I'm guessing it's a wear indicator and once the pads get wore down enough, it starts to contact and squeak on the caliper bracket, not sure so where should I put it?




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Also, each individual pad came with one of these what I assume to be an anti rattle brake pad clip, but for the life of me, I can't figure out where it goes.  Any ideas?

I think that's enough for tonight.  More to come...


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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bob W Quote  Post ReplyReply Direct Link To This Post Posted: 03 July 2021 at 7:00am
Originally posted by Scratch Scratch wrote:

For my second question, if you notice on the "dust cover" above, there is a raised hump, but I can't remember where that was supposed to go.  On the top, on the bottom... does anyone know?  I see an extra hole in each of the other plates, is that supposed to line up with the hump, and if so, where do I clock it to?

The hump and the extra hole go to the bottom and line up with the extra hole in the axle housing flange. It is an escape path for anything that leaks past the seal. Looks like the caliper brackets don't have the extra hole so it really wont matter which way they all face.


Edited by Bob W - 03 July 2021 at 7:03am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bob W Quote  Post ReplyReply Direct Link To This Post Posted: 03 July 2021 at 7:15am
I'd like to find out more about the steering on your "salad Jeep"! Do you have more photos or a build thread anywhere?

Thanks
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scratch Quote  Post ReplyReply Direct Link To This Post Posted: 03 July 2021 at 1:10pm
Originally posted by Bob W Bob W wrote:

I'd like to find out more about the steering on your "salad Jeep"! Do you have more photos or a build thread anywhere?

Thanks
No, I built this around 2002 and joined here around 2019 so I never did a build thread.  I do have some info though...
I found this 47 2A with a bad engine but good tub.  



I had this 65 CJ5 with, lets just say not much sheetmetal left...



I got rid of the leftover sheetmetal, then stripped and painted the drivetrain.



Did the standard "bare bones yard drive" before the tub was installed...



Here are a few pictures trailriding.  I installed a Holbrook long leaf kit soon after I started trailriding it.  It gave me lots of flex and 3" of lift for the 31" Terra tires.  







At some point I decided power steering would be nice with those wide tires, and I had a Scout with power steering that was junk, so I pulled the pump, steering box and column from it and put it in the Jeep.  This spring the rag joint went bad so I got a new steering joint from Anything Scout and it works much better!





Here are a few more recent pics of it, along with some of my other projects.





Edited by Scratch - 03 July 2021 at 1:37pm
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
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Rus Curtis Quote  Post ReplyReply Direct Link To This Post Posted: 03 July 2021 at 1:13pm
Nice collection!
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While I was waiting to figure out where the brake pads and clips went, I started on the dual reservoir master cylinder.  This is what came in the kit from KW, along with the factory MC.




I have to tell you... installing this thing was the worst part of this whole process.  I didn't get any pics during the installation of this thing because I was too busy swearing.  This dual reservoir master cylinder would definitely be MUCH easier if the tub was off.  I had to cut off the factory MC bracket, remove the exhaust so I could fit in the new bracket, and somehow transfer the hole locations to the outside of the frame for drilling.  Once that was done, it was just a matter of bolting it up.  It took me a while, but I managed to do it.




Edited by Scratch - 03 July 2021 at 9:19pm
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: 03 July 2021 at 9:15pm
I'm not sure why I didn't think of this before when trying to figure out how the brake pads went or where those clips were supposed to go, but I finally just watched a YouTube video on putting brakes in a '95 Sidekick.  The clips go on the caliper bracket, not the caliper.  Problem solved.





Edited by Scratch - 03 July 2021 at 9:20pm
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
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Post Options Post Options   Thanks (0) Thanks(0)   Quote BD1 Quote  Post ReplyReply Direct Link To This Post Posted: 04 July 2021 at 8:34am
Hump on the dust cover goes down. It lines up with the grease drain hole in the axle flange. The drain hole is the one that doesn't line up with any of the bolts

Edited by BD1 - 04 July 2021 at 8:41am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote BD1 Quote  Post ReplyReply Direct Link To This Post Posted: 04 July 2021 at 8:37am
Also, on my Brennan plates I had to drill out the drain hole in the plate once I decided what position I wanted the plates clocked to.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 20 July 2021 at 8:57pm
Hi Scratch!  Looking good!  I'm a little late to the party but we did the same conversion last year on mine and my brother's jeeps.  You can check out my conversion pics on Photos and Stories - Barrys Builds - page 3.  Like BD1 I drilled drain holes thru Brennens plates to keep water from pooling in the dust covers.
In this pic you can see thru the drain hole.  The hump in the dust cover lines up with it.

I purchased the skinny Wilwood dual master with remote resivors but havent installed it yet.  Still using the stock master and works great,  just want the safety of 2 separate circuits in case I puncture a line.  Thanks for sharing!

-Barry
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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 1:13am
Originally posted by Barry S Barry S wrote:

Hi Scratch!  Looking good!  I'm a little late to the party but we did the same conversion last year on mine and my brother's jeeps.  You can check out my conversion pics on Photos and Stories - Barrys Builds - page 3.  Like BD1 I drilled drain holes thru Brennens plates to keep water from pooling in the dust covers.
In this pic you can see thru the drain hole.  The hump in the dust cover lines up with it.
I purchased the skinny Wilwood dual master with remote resivors but havent installed it yet.  Still using the stock master and works great,  just want the safety of 2 separate circuits in case I puncture a line.  Thanks for sharing!

-Barry
Thanks, I just checked out your build and wished I would have found it first.  I like the idea of welding on the spacers!
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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