DANA 44 Disc Brake Conversion Part 2

In this video, I finish up the disc brake conversion on Project Tetanus' Dana 44 rear end.
Part 1: • DANA 44 Disc Brake Con...
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This product is meant for entertainment purposes only. Your mileage may vary. Do not try this at home. Void where prohibited. Some assembly required. For off-road use only. Slippery when wet. Batteries not included. Do not use while operating a motor vehicle, heavy equipment, cherokee XJ, wrangler TJ, wrangler JK, or any Jeep vehicle, especially the newer Fiat ones. How-to videos may be too intense for some viewers and children under 30 years of age. Please remain seated until the 4x4 ride has come to a complete stop. Studies have shown viewing these videos causes increased cancer risks in laboratory test people. I am not a professional, I have no training, I'm not even particularly good at horse whispering. Don't believe everything that you know. Please keep your hands in the vehicle at all times. Do not tap on glass. Do not eat anything that has been on the floor for more than 3 days. Keep your hands to yourself. Not to be taken internally. Reproduction strictly prohibited. Driver does not carry cash. Objects in Bleepinjeep mirrors may be farther than they appear.
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[@Dillithium]

This is truly impressive. Not only in its ingenuity, but in your selection of easy to come by parts and execution. I really, really like this idea. I scored some ZJ rear brakes from a junkyard to eventually attach to a chryco 8.25, but these brakes seem much better. With the addition of a line lock hand brake, I feel it would be even better. No more nasty drums and shoes, just easy to maintain and replace discs all around. The only hurdle for me are the brackets. You're quite lucky to have a friend who can cut those out for you. I think combined with a WJ front brake upgrade, any Comanche/Cherokee will stop on a half a dime. I'm going to have to rewatch part one, to figure out how you drew a design for those brackets. I'm planning to do this on a 8.25, but it should not be very different. Let us know how the brakes are once you're done! I know you usually do not notice much from rear brakes, but with equal size brakes front and back, it's bound to make a difference. Thank you for posting this.

[@tylerbleepinjeep606]

+Dillithium I got impatient with Part 1 and didn't really show how I made the chipboard pattern. Maybe it deserves its own video. I'll see what I can do for you. There are several ways to cut out the steel once you have your pattern made. I just took the easiest path available to me. I'm sure it could be done with a hand-held plasma cutter or a good torch and some patience. Don't let the bracket discourage you, it wasn't as hard as I thought it would be.

[@jgsb111]

First time welding with that machine and you just went for it? You're a savage. Also, keep it up man. Love this series!

[@MufflerDindin]

I installed an electric line lock to the front brakes that I use on the trail for short stops...I wired a 12-volt chime from Radio Shack into the rocker switch so that I always know when it's engaged (it's way too annoying to ignore or use for extended stops). I also installed a mechanical line lock from Jeggs to the rear brakes for parking when the Jeep is turned off. The lever is hidden and therefore also works as an anti-theft device. Between you and Matt I am constantly inspired and educated in matters of upgrading and repairing my old YJ.

[@coachd6100]

Great ingenuity! I'm glad you go through the thinking so others can just 'copy & paste'. Saves a lot of Jeepers a lot of time (and money). Thanks! Keep these vids coming!

[@rc3140]

Nice job,you have given everyone another option for rear disc brakes 👍

[@et_2brutus640]

Good stuff... definitely looking at this for the XJ. Well Done!

[@Tater79bj]

Am I the only one that noticed the Glock sitting on top of the welder lol.

[@et_2brutus640]

+Tater79bj For weld-haters. No one hates on your welds when there's a Glock parked on the welder.

[@Tater79bj]

+Crash TheStampede lol, best reply ever!

[@bleepinjeep]

+Crash TheStampede BWAHHAHAHAHAH!

[@DaGreatWaaagh]

this comment had me dying

[@txgamer1347]

That's a damn good weld at 3:28

[@tylerbleepinjeep606]

+TxGamer13 Thanks!

[@watrousmark401]

A line lock set up to the front circuit also would give you four wheel E brakes and could really help during winching operations if you're the anchor.

[@TDONLEY91]

there is a bolt on way to do it with Ford explorer rear brakes and you retain the emergency brake. you just have to use a Rubicon spacer.... and redrill it xj Dana 44 pattern for axle bearing seal. pretty easy and no welding required

[@richtyler1353]

Such great information very instructive thank you

[@kevinhornbuckle]

This is an excellent project. Of course your welds are less than perfect. You are learning. That Hobart seems to work well. I would say that heat management is something to plan for because you don't want to distort the bearing races. Also, maybe multiple passes would be the way to go. And maybe jump from side to side so that it doesn't pull. But you go it. The only other thing I would advise is to treat your body right by getting that up on a bench so that you don't have to weld bent over. Your body deserves to be comfortable and your hands will be more steady. I'm looking forward to the line lock for the parking brake. I would be cool to see that operated by a hand lever in the cab.

[@michaelroberts9253]

I was a. Floor tile man. For. About a year and half. I also worked hanging drywall an metal studs for 40 plus years ,and all take toll on your needs an joints I'm paying for it. Now. I was 62. Yesterday. Thank Lord For another day ,?

[@michaelroberts9253]

Work off a work bench alot more comfortable an easy .

[@eclifton4070]

Would you mind adding a link to the calipers you used? I'm getting ready to do this on my Willy's Wagon. Thank you for this. It is exactly what I was looking for.

[@LZDEN]

very nice indeed.

[@EKonMaster]

I have to try this

[@michaelroberts9253]

Line lock or Hurst roll control ??

[@janarvahtras2073]

Use the vw rear brake calibers with handbrake. Brake caliper rear axle right side / co-driver side - OEM Ref. 7H0 615 424 / 7H0 615 424 AVW T5 Transporter (7H,7E,7J)All types - Transporter, Multivan, Caravelle, PritscheAll engines up to 2.5 TDI 128kWSystem TRW for 294mm brake discs rear41mm piston

[@inkybinkybonky3901]

Where I can I get those brackets?

[@gibsalot]

on your positioning of the calipers , front disk calipers are mounter on the upper rear side of the axle , but most every rear disk caliper i have seen is mounted on the upper front side of the axle. it looks to me like your's are mounted on the upper rear side.

[@gibsalot]

+gibsalot not sure if that makes much differance or not.

[@tylerbleepinjeep606]

+gibsalot I mounted them upper rear. that's where they are on my 9" and I've been really happy with it. Figured it would work fine on this D44 too.

[@ericsoto2684]

Do you know if a d44 out of a 1987-1989 Cherokee will bolt right into a 2000 cherokee

[@camronboldenow2973]

Eric Soto yes it will, just did it to mine

[@whatnotzone6866]

A grinder and paint makes me the welder I ain't!

[@tree18is]

yall got anymore of them brackets *scratches neck*

[@patriciafrost6906]

I like your work and ideas ,I want to do the same thing to my Comanche , but will this setup allow for my 15” turbine wheels again thank you for sharing your work

[@adamformanack6700]

A line lock is more of a secondary back up , but the mechanical brake caliper is always a primary oh shit,.!!!! man glade I had that,..it save my ass....😎✌

[@matthewgregerson5038]

Your emergency/parking brake provision, per State LAW, in many IF NOT ALL States requires it to be separate from the service brake system and mechanically operated, you cannot use a Line-Lock and have it DOT OR State legal and pass State safety inspections if the inspector is doing their job correctly. Might want to check on that in your own State to be sure, but here in Pennsylvania, that's the way it is supposed to be.

[@adamformanack6700]

Dude!!!!! were is the E-BRAKE , safety first ..😎✌ your rig will roll off the mountain

[@rheidtech]

kikass bud.

[@michaelroberts9253]

Any fab shop willcut those brackets an use Eldorado calipers emergency brake system, 1 ton. Chevy calipers when u update to Dana 60s.

[@GorillaCookies]

Interesting neighborhood you live in if you have to have a Glock in arms reach while welding in your shop. I'm a Beretta man myself and oddly enough Im glad I had a 92fs on my work bench one night because a half starved and clearly desperate mountain lion decided to try and make me its next meal. Even half starved and probably weakened it took 3 hollow points at point blank range to stop the big cat as it came at me in my shop in 2017

[@xmo552]

And I go hiking with a knife thinking that'll be enough to save my skinny ass against a mountain lion. I should invest in bear spray.

[@michaelroberts9253]

We. Have screaming 😱 black. Panthers here in Mississippi an they will make your. Hair. Stand up ??