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1991 - 2001 Jeep Cherokee XJ. How to actually Disc Brake swap a Chrysler 8.25 Rear Axle. Here, the process shall be documented in a valiant effort to display what it's actually like, things that actually happen, and how much time and money it actually cost.
1990 - 2001 Cherokees and Comanches with a Dana 35 can use Grand Cherokee ZJ (1993 - 1998) parts instead of Jeep Liberty (2003 - 2007) parts for the same result, which will also be a bolt-on conversion with no welding required.
1984 - 1989 Cherokees and Comanches with a Dana 44 or a non-c-clip Dana 35: the process is different but overall similar. Check out Nick’s video on his 1989 XJ: • 89 Cherokee Dana 35/44...
Which Rear Axle do you have?: • How to Identify Which ...
What is Brake Bias and why is it important?: • Why are Front Brakes L...
Why bigger brakes won’t actually stop your car faster: • Why Big Brakes Won't S...
Thanks to Bryant for his knowledge and assistance on this project: / @xj_overlander
YOU WILL REQUIRE:
-03-07 KJ Backing Plates
-03-07 KJ Backing Plate to Axle mounting studs
-03-07 KJ Parking Brake shoes and hardware (new)
-03-07 KJ Rear Brake Rotors & Pads (new)
-03-07 KJ Rear Calipers & Banjo bolts (new)
-99-04 WJ Rear Rubber brake lines
-84-01 XJ Dana 30 wheel studs (x10)
-93-98 ZJ Proportioning Valve Spring
-97-01 Disc Brake compatible Parking Brake Cables
-84-01 Pre-Flared Brake Lines 12” & 40”
-97-01 XJ Front Parking Brake Cable & Equalizer
-91-04 XJ Rear Axle Wheel Bearing TIMKEN 6408
-91-04 XJ Rear Axle Wheel Seal TIMKEN 8835S
-97-07 XJ Differential Center pin bolt
-91-07 XJ Differential Cover Gasket
-Differential Fluid
-Wheel Bearing Puller 57129 (Autozone)
This project cost me a grand total of $568.17 for everything. However, on a budget, I could have done it for $304.93. Either way, a lot cheaper than the $857.53 for a “kit”, and a lot more expensive than about $150 to completely overhaul the existing drum brakes.
TO THE JUNKYARD:
-Sockets 10mm to 15mm
-14mm Deep Socket
-8mm Ratchet Wrench
-Needle-nose pliers
-Hammer
-Prybar/ Large Screwdriver
-Something to cut parking brake cables with, because you ain’t getting them off.
-A Crescent Wrench, because the Proportioning valve caps seem to vary in size from 13/16” to 3/4”
-Jack/ stands
-A drain pan (?)
PART LINKS
-KJ Rear Rotors: www.rockauto.com/en/catalog/j...
-KJ Rear Brake Pads: www.rockauto.com/en/catalog/j...
-KJ Rear Calipers: www.rockauto.com/en/catalog/j...
-Powerstop Caliper Compatible Banjo Bolts: rb.gy/gn94k
-KJ Parking Brake Shoes: www.rockauto.com/en/catalog/j...
-KJ Parking Brake Hardware Kit: www.rockauto.com/en/catalog/j...
-Parking Brake Equalizer: www.amazon.com/dp/B07GNKMNGP?...
-97-01 XJ Rear Disc Swap Parking Brake Cables: www.quadratec.com/p/crown-aut...
-Front Parking Brake Cable:
www.rockauto.com/en/catalog/j...
-Rear Axle Wheel Bearings: www.rockauto.com/en/catalog/j...
-Rear Axle Seals: www.rockauto.com/en/catalog/j...
-Dana 30 Lug Studs: www.rockauto.com/en/moreinfo....
-WJ Rear Left Brake Hose: www.rockauto.com/en/moreinfo....
-WJ Rear Right Brake Hose: www.rockauto.com/en/moreinfo....
-Chrysler 8.25 Center Pin Bolt: rb.gy/v5888
Keep the drums instead: www.rockauto.com/en/moreinfo....
Can’t Stop: • Punch Deck - I Can't Stop
Offworld: • HurricaneTurtle - Offw...
Dominant: • Punch Deck - Dominant
00:00 The Intro
00:04 The Premise
03:50 Phase 1: Find the Parts
07:15 Phase 2: Operation Begins
07:55 Differential Teardown
09:17 Lug Nut Studs
10:31 Remove Brake Lines
11:05 Remove Drum Brake
12:07 Backing Plate Studs
13:11 Wheel Bearing
16:16 Backing Plate Install
17:07 Parking Brake Shoes & Hardware
21:39 Axle Shaft Install
24:21 Differential Assembly
29:16 Brake Rotor & Parking Brake Adjust
30:37 Brake Caliper
32:42 Custom Brake Lines
34:36 Differential Cover and Fluid
35:29 Proportioning Valve
36:50 The Master Cylinder
39:36 Parking Brake Cables
45:06 Routing Rundown
47:04 Initial Test
50:04 Final Thoughts