JEEP XJ REAR DRUM TO DISC - HOW TO DO A CHEROKEE DISC BRAKE CONVERSION - ZJ DANA 35 TO CHRYSLER 8.25

Here's a detailed tutorial on how to convert the drum brakes on your XJ to disc brakes. For this installation I went with a ZJ D35 brake set up on an XJ C8.25. Its been a very long time in the making, thank you for your patients and thank you for watching! #Jeep #Cherokee #XJ #lifted #reardiscbrakeconversion
Feel free to use the links to all the products in the description.
Teraflex Conversion kit - amzn.to/3zvoCIK
DISC CONVERSION PARTS
(2) Rear Caliper Phenolic Piston - Carlson CK 7718 - amzn.to/3lCMa5H
(1) Parking Brake Hardware - CENTRIC kit 118.61037 - amzn.to/32KobZD
(1) Parking Brake Shoes - MONROE Rear BX701 - amzn.to/2QJI4dZ
(2) Rear Caliper Seal & Gasket - CENTRIC 143.61019 - amzn.to/2QLEEYc
(2) Rear Rotor - POWER STOP AR8732EVC - amzn.to/3bmu1UX
(1) Rear Brake Pads - ACDelco Ceramic 14D666CH - amzn.to/34Vxp80
(1) Caliper Pin Rubber Dust Boot ARI INC. 7832011
(2) Parking Brake Lever Boot - Crown Automotive 5093395AA - amzn.to/3hUCeSQ
(1) Passenger Side Parking Brake Cable - Crown Automotive 52128510AG (03-07 Jeep Liberty KJ)
(1) Driver Side Parking Brake Cable - Crown Automotive 52128511AF (03-07 Jeep Liberty KJ)
(1) 3\8"-24 Brake Bleeder screw - Dorman 13901/12701 - amzn.to/3gT4DHw
(2) Copper Hydraulic Crush Washers - Mopar OEM 6502114 - amzn.to/3gQ76Cz
OTHER PARTS
C8.28 Axe bearings and seals - amzn.to/3D8Lui9
(10) Grand Cherokee ZJ 1993 Wheel Stud - amzn.to/3jzuXby
(2) Rear Caliper Bolts and Pins - Dorman HW5066 - amzn.to/32NI428
Parking Brake Lever Kit - Dorman 926-293 - amzn.to/3jCvZUk
(2) Rear Caliper Bolts and Pins - Dorman HW5066 - amzn.to/32NI428
(2) Rear Caliper Bolts and Pins - Dorman HW5066 - amzn.to/32NI428
L & R OEM Brake Calipers 1993-1998 ZJ (Parts Car)
L & R OEM Disc Brake Dust Cover plate 1993-1998 ZJ (Parts Car)
L & R OEM Disc Brake Backing plate 1993-1998 ZJ (Parts Car)
Proportioning Valve, Cap, Spring 1993-1998 ZJ (Parts Car)
Brake Hose Kit - Crown Automotive 52007401 1993-1998 ZJ (Parts Car)
(8) Backing Plate Studs & Nuts 1993-1998 ZJ (Parts Car)
LIFT COMPONENTS
G2 C8.25 Diff Cover - amzn.to/3CUu4au
UPPER REAR SHOCK FLAG NUT BRACKETS - amzn.to/3cHbyI3
ROUGH COUNTRY 3 INCH LIFT - amzn.to/3CAAziz
ROUGH COUNTRY TRACK BAR 0-3.5 INCHES - amzn.to/3CDkY1z
ROUGH COUNTRY SWAY BAR END LINKS - amzn.to/3wBcFZzJ
MOOG SWAY BAR BUSHINGS - amzn.to/3pW1WvG
MOOG UPPER CONTROL ARM BUSHINGS (AXLE SIDE) - amzn.to/3cpQZzs
UPPER CONTROL ARMS - amzn.to/3AvKfbx
AXLE SEALS - amzn.to/3PQ4ZjK
REAR SWAY BAR BUSHINGS - amzn.to/3AKMw2w
REAR SWAY BAR END LINKS - amzn.to/3wRcKzq
INSIDE THE OIL PAN
JEEP XJ OIL PAN - amzn.to/3xtQ34m
FEL-PRO OIL PAN GASKET - amzn.to/3BJQief
FEL-PRO 40183 Rear Main Seal (2000-2001) - amzn.to/3xrArhX
FEL-PRO 40612 Rear Main Seal (1997-1999) - amzn.to/3U70FQq
FEL-PRO TIMING COVER GASKET - amzn.to/3BJwXd0
MELLING OIL PUMP - amzn.to/3BJRo9R
TOOLS USED / DAN H FAVORITE TOOLS!
DEWALT 20V Max XR Impact Driver Kit -1/4-Inch (DCF885C1) - amzn.to/3NtnPff
DEWALT 20V Max XR Impact Driver Kit -1/2-Inch (DCF899M1) - amzn.to/3NDhgGZ
GEARWRENCH SAE/Metric Ratcheting Wrench Set - amzn.to/3OQq6lU
Impact Bit 6" Socket Extensions -1/4” 3/8” 1/2” - amzn.to/3a2DN2y
Ares Fan Clutch Tool - amzn.to/3kPryIq
PRODUCTS USED
CRC synthetic brake & caliper grease - amzn.to/3bfeTc4
Eastwood Rust converter - amzn.to/3QPTWbD
Rust-Oleum Self Etching Primer - amzn.to/3wFghR5
Rust-Oleum Semi Gloss Black - amzn.to/3RjAfZJ
Brake Clean - amzn.to/32ESfKe
Microfiber cloths - amzn.to/3o9xzS9
Permatex High Temp Gasket Maker - amzn.to/34d1otY
SeaFoam Deep Creep - amzn.to/3L6mFVP
Movie Clips:
Austin Powers Gold Member - "Preparation H"
Daniel 2.20 Blessed be the name of God forever and ever for All wisdom and power are His.
Hey, what’s up, guys? I hope you enjoyed another project. Please remember that this video product is meant for entertainment purposes only and intended for people of driving age, and that is not “made for kids”. Also Please Keep in mind I am not a professional and I have no professional training so don’t try this at home. If you decide to modify or fix your own vehicle please keep it legal, roadworthy, and most importantly SAFE. Thanks for watching and I’ll see you on the next project! ✌

[@ProjectDanH]

It's finally here! 🙌🙌🙌🙌🙌🙌🙌🙌

[@pjorlando7017]

Nice job Dan. I believe that black plug in the cover is the full level indicator. When it comes outa there it’s full. That’s why you got a gallon in that thing lol.

[@ProjectDanH]

Hahahahaha! Oh well!

[@rperron3439]

Nice to see a new video DanH. I also have an XJ(2001) and have some parts for a rear brake ZJ disc conversion. One thing I did do as I have a budget boost rear leaf pack, I used a YJ rear soft line on my XJ as it’s a little longer. Don’t know a part number but it should be an easy part to grab at a local auto parts store. Look forward to seeing the stretch XJ in the future.

[@ProjectDanH]

Thanks brother! Yes there's definitely a bunch of other parts that can be utilized for completely custom swaps!

[@melton_r3557]

Ive been waiting for this video forever😅🙌

[@ProjectDanH]

LOL, Me too Brother, Meeee toooo!

[@walterlegere1403]

A lot of great info! One of the best disc swap videos I've seen on the XJ rear break swap! Well done mate! I didn't know you could just swap the guts to the proportioning valve. I've got a rare 92 XJ 2-door High Output 4.0 with an AX-15 5-speed, an NP-231 transfer case, Dana 35 rear, 4" lift and lockers front and rear. I deleted the anti-lock breaks because I put off-road rated chrome molly 27 spline axles in the back because I was told the stock axles would not hold up with a locker. Changed the 3.07 gears to 4.10's from an 89 YJ high pinion set up. Off road and hill climbing, this thing is a beast! This is my next project so THANK YOU for all the hard work and excellent detailed info on the swap!

[@15farcry]

That is a really clean, oem looking conversion. Great job Dan!

[@ProjectDanH]

Thanks Brother! If your gonna do it... Do it clean!!!

[@1stzjtruck706]

Great job Dan. keep it up. God bless you and your family.

[@ProjectDanH]

Thanks brother, you too!

[@Deadbuck73]

Awesomeness! Thank You for showing us the way!

[@ProjectDanH]

My pleasure brother!

[@gryffydd42]

Nicely done. I used the same differential cover, but in black. BTW, the black plug is the fill level. You remove the black plug and the red fill plug, and then add fluid. When fluid comes out of the black plug location, you are good. I did liberty brakes on my 93 sport and the only differences of install are the backing plates fit as is, and you can buy/use e brake cables from conversion kits (I used crown disc conversion cables) because they are equal length until 1997 and up. I think I saw somewhere that cables from certain years of Ford Explorer fit the 97-01 xj disc conversion. When I put the ZJ hoses on, we cut bracket into L shape and then bolted it to one of the leaf stack bolts- worked perfectly. Great to see this done, and hope you can get this on the general eventually.

[@ProjectDanH]

Thanks Andrew!!! I was wondering why the new cover took so much oil! Haha mine didn't come with any instructions! Lol 🤷

[@vagnertutano8587]

Awesome Dan H I was waiting for this video! Thank you for sharing it . Also I can wait to see what you did to drop down your transfer case . Peace ✌️

[@ProjectDanH]

Thanks brother!

[@jacekwieczorek7586]

Already have conversion on my 97' but watched your video anyway. Great work!

[@ProjectDanH]

Thanks brother!

[@JoeVizethum]

geeeaaat job, pal - helpful and entertaining as always !

[@ProjectDanH]

Lol. Thanks bro!

[@Ozzy5610]

Great attention to detail, the WreckedJ looks amazing Dan! 👌🏼

[@ProjectDanH]

Thanks Brother! Sure did come along way

[@Boobie5936]

Great informative video 🦾😎

[@xcb7n2]

Great Job Dan! Your content is well-planned (or edited ;) Not only did I learn how and the parts I need but I REALLY appreciate your well-spoken manner, good audio/video quality, and lack of senseless babble that is profuse on so many other channels! I'm not even a Jeep owner but will be using many of these same parts to complete a similar swap for a 70 Satellite project and this was perfect. You earned a new fan/subscriber!

[@ProjectDanH]

Awesome, thank you! I appreciate your kind words and maybe one day you can join the Jeep struggle too!! lol

[@mudhound0530]

Excellent video!

[@ProjectDanH]

Thank you!

[@myjeepwjarebuildpaulsteven7986]

Great video ✅

[@alexpodel778]

I've also had the parts for this conversion sitting in my garage for a year now. Maybe I'll actually use em one day.

[@ProjectDanH]

Haha! Go for it!

[@Fuckyoutubecensorship1]

​@@ProjectDanH What was that kit that you mentioned earlier in the video for the disk brake conversion can you please link it???

[@greenhead333]

Love and appreciate your how to videos

[@ProjectDanH]

I appreciate that!

[@mclehed77]

Niiiice job Dan she looks awesome 👍🏾😁

[@ProjectDanH]

Thank you!!

[@Tophershawn_]

Great video! Thank you

[@ProjectDanH]

You are welcome!

[@vet-7174]

Good Vid Dan, Now I know how to do it 🖒🖒

[@ProjectDanH]

Thanks brother!

[@MacsSpecialitiesMotorsports]

Nice Vid~ First Time Viewer!

[@ProjectDanH]

Thanks you!

[@never-stock-rc2968]

So sick!!!

[@ProjectDanH]

Thanks!

[@jaysmith5084]

Dan H great job on the rear brakes and install 👍 I think this channel would be 500k subs if you put out more videos because you actually work on all the Jeeps aka restore them on a budget. How's the Commander doing anything new with that one ? Keep up the good work 😎

[@ProjectDanH]

Thank you so much man! Hard to get content out lately with four kids and a full-time job but I'll do my best! The commander is looking at a 3-in lift and 33s soon!

[@jaysmith5084]

@@ProjectDanH we will need a video of the lifted Commander for sure !!

[@Marc-XJ4.0]

Nice work - what might help is to get the rubber brake hose combination line for a 95 YJ - that is a longer rubber line & its stock fittings for the rear - Great Job 👍

[@ProjectDanH]

Thanks bro!

[@millerzionZ3]

Great video I’ll be doing mine soon I’m gonna get a jeep liberty rear axle any tips I should look forward to ?

[@shawnmrfixitlee6478]

nice job .. FOREVER JEEP.. OIIIIIIIO

[@MacsSpecialitiesMotorsports]

#ShawnMrFixitlee you meant Forever JEEP []IIIIIII[] 😆

[@shawnmrfixitlee6478]

@@MacsSpecialitiesMotorsportsOld or new it's all good in a Jeep !👍

[@MacsSpecialitiesMotorsports]

@@shawnmrfixitlee6478 you got that right!

[@ProjectDanH]

Thanks bro

[@AEWYU]

With the studs on the backing plate! You can also use the studs from the front of the xj

[@ProjectDanH]

Any stud that's longer. Lol!

[@Chris-fl6fx]

Great video and good job 👍 Is there a conversion possible that’s reusing the abs? Greetings from the Netherlands🇾🇪

[@jammerlupardi8782]

Nice job Dan, aren’t you worried about the brake line running under the axle, something my snag it and good bye brakes……

[@timothysimpson912]

Can hardly wait for you to do the Dana 35 with ABS conversion. I have all the parts. Had to go back for the proportioning spring and ZJ shafts with the ring gear. I see there is a difference in the ZJ and XJ ABS rings and apparent;y not compatible. I am assuming you will still have to cut that notch out so I will wait to see the master do his thing. God Bless!

[@ProjectDanH]

Yes, you will have to cut the notch! Looks like you'll be conquering it sooner than me. let me know how it goes!!!

[@martinkuhne452]

Dan, nice Video, but I think you put the brake pads in the wrong orientation. The pad must engage on the lower side first, then flip it over. In the Video you engaged on the top...

[@ProjectDanH]

Hey! Great eye! Sometimes I overlook little things while filming.. it happens 🤷

[@kumaquattro]

First time seeing your video, great job, but I would have torqued down the diff cover .

[@ProjectDanH]

Thanks man!

[@BluecollarOtaku]

Loved the video Dan! Great job. I ended up doing my disk conversion back in July. Did you have issues adjusting your e-brake cables? The install looks really clean with where you welded in the brackets. I’ll send you a pic of my install with out welding, seems to do the job.

[@ProjectDanH]

Yes, adjust the cable is the worst. Lol . Then once you dial it in they stretch! Haha. Maybe I'll get explorer cables later

[@BluecollarOtaku]

@@ProjectDanH yeah, they can be a pain. Explorer cables work? What year and model? Besides the ebrake adjustment, I love the swap so far well worth it and your videos helped a great deal!

[@hassanalrashied9565]

good

[@ProjectDanH]

Thank you

[@Projectgearheads]

Great video I’m basically doing the same thing, I looked at so many videos and yours was the most simple video I found. I do have a question have you had any issues with the brake cables ? I know you said they were little longer that’s the only thing I left to purchase….. Thanks Dan.

[@ProjectDanH]

Thanks for Watching!!!! the cables work fine, but without a big lift you'll have to rout them where they wont interfere.

[@jeepdiscbrake8329]

youtube.com/@jeepdiscbrake8329?feature=shared

[@agustinhidalgo405]

Which proportioning valve do u recommend when upgrading to rear disk.

[@lwil6393]

Here is an alternative brake line set up, simply bend OEM line near vertical, bend hose bracket slightly and drill and tap 1/4 or 6mm hole to mount the hose bracket. to top of spring hanger plate. Tried to send photo but no go.

[@albertobynoe4506]

Good afternoon Mr. Dan. I am in desperate need of a bolt for my Crank Position Sensor .What other jeep can I look for this Bolt? A.S.A.P Please.

[@street_wise_gamgee]

ive done this swap on dana 35 and 8.25 using zj brakes the 8.25 u need to grind the bracket a bit to fit over the tube. never swapped the prop valve didnt need to it worked fine as is. super easy and straight forward swap. but your better off swapping a ford 8.8 axle in.

[@ProjectDanH]

LoL. I didn't have an extra 8.8

[@street_wise_gamgee]

@@ProjectDanH probably 1 of the best swaps ive ever done to my zj thats for sure. ford 8.8 with 4.88s and artec truss kit.

[@CJLane-62]

1st time viewer and a new subscriber,question, how do tell the difference between the D35 and the 8.25 Chrysler differential,on a '96 XJ, 1st time XJ owner here,took the axle codes to my local Jeep dealer service department and they said that Chrysler don't give them the codes,they go by the vin #?

[@ProjectDanH]

Chrysler 8.25 Looks flat on top and bottom of the Dif Cover, whereas as the diff cover on the D35 is more of a smooth oval all over.

[@CJLane-62]

@@ProjectDanH Thanks😁,now all I have to do is crawl me old bones under it and photograph it so I can see it better, and hope I can get back up off the Cold concrete without help!🤔

[@alexnegron7561]

Hi Dan i like yours videos .i have a 2000 xj and it got a 3 in lift what size of shocks you have in the in your xj thank you

[@ProjectDanH]

Thank you! I bought the rough country N3 shocks from their kit

[@alexnegron7561]

Thanks again

[@michaelguglielmo2749]

You might want to see if you can fab up a mount for the rear brake line , not a good idea to have it flop around. That line will fail at the hard line to chassis mount.

[@ProjectDanH]

Good idea

[@915Performance]

@@ProjectDanH You can use a brake line from a Dodge Dakota cant remember the year but its way longer then the XJ great for diy lifts!

[@hayzersolar]

the bracket you welded for the brake line will that get hit when you go off road? looks to close to the ground

[@ProjectDanH]

Its possible but we don't off road this jeep. It could be mounted higher for off road use

[@ericgunnyporter8964]

Hey Dan I have a question for you what paint did you use to paint the underside of the wreck J . I have Rustoleum professional spray paint and POR 15 what did you use. Thanks.

[@ProjectDanH]

I use both por15 and Rust-Oleum 😁

[@ericgunnyporter8964]

@@ProjectDanH Thanks Dan I will upload a picture of my XJ once its completed

[@sotres1]

i have a 95 4 cylinder manual xj i am not into offroad this is my daily car i have read on several forums to do the 4 hole injector to get a bit of performance whats your thought on this ? thanks in advance

[@ProjectDanH]

4 hole injectors are great. I've done this in all my XJs!

[@toddrhine7648]

@@ProjectDanH What's that all about when that gut said when upgrading from a single hole Injector to a 4 hole you have to have a larger intake hole. I have a 93' Grand Cherokee Laredo I6 4.0 and was thinking about upgrading mine to a 4 hole Injectors also. What's your take on all of this? Thx in advance for your time.

[@VenturaIT]

Is that why C-clips are considered bad for off-road, if you bump your wheels/tires just right, they come off or is that only possible if the rest of the insides of the diff are already out?

[@ProjectDanH]

C clip rear axles without disc brakes are bad for off-road (or on road with huge tires) because of the axle snaps the whole wheel will slide out. Adding disc brake will keep the wheel on if the axle snaps apart

[@VenturaIT]

@@ProjectDanH Got it, thanks.

[@robertweinstein6441]

What about the e brake hookup! What comes from the drums to the e brake cables.

[@ProjectDanH]

I used KJ cables

[@deadspeed6679]

I would never hang brake lines under a axle tube if it gets hung up on anything while trailing good luck

[@ProjectDanH]

Not trail this one, but thanks for the input!

[@rustylindamood4898]

Are you using wheel spacers the the stock wheels ?

[@ProjectDanH]

no spacers needed

[@johanna.browne]

I have no abs and a Dana 35, not the 8.25 Chrysler. Would this work on m my 96 sport?

[@ProjectDanH]

yes absolutely

[@raexcct2]

​@@ProjectDanH, Thanks for the answer as that is what I also have, a 1996 Jeep Cherokee Sport.

[@ky0611]

I never understand the portion valve and changing the spring. What exactly does it do using the ZJ spring?

[@ProjectDanH]

It portions less fluid to the rear so the disc brakes wont lock up.. rear skidding is bad

[@ky0611]

@@ProjectDanH so I bought a g2 rear disc conversion but it didn't come with a spring for that. Should I still be looking to change it?

[@ProjectDanH]

@@ky0611 only if your rear brakes are locking up

[@ky0611]

@@ProjectDanH o ok Thanks, In all the other videos I've watched they talk about it helping with braking better. But none them talked about it helping not locking up the rear

[@Fuckyoutubecensorship1]

You said that liberty is better in order to do a dis break conversion what was that other thing you said can you post a link to it????

[@ProjectDanH]

ZJ for a D35. KJ for a c.825 Teraflex Conversion kit - amzn.to/3zvoCIK

[@Fuckyoutubecensorship1]

@Project Dan H Thank you man I really appreciate it keep up the good work 🇵🇷.

[@garyvanmeter4911]

@@ProjectDanH I have a D44 from a 1 Ton Comanche MJ to install in my 93 XJ. Do I get donor brakes from a late ZJ with disks?

[@wilmermejia8645]

Hey will do a similar job for someone else.??

[@ProjectDanH]

sure

[@stevenwebb2295]

I'm assuming you didn't want to spend the money on a locker? I think I would have stuck my mig gun in with those spider gears and pulled the trigger before I put that new cover on my diff. 🤣I wouldn't have been able to help myself. I shop at harbor freight these dayzzz, so I guess that would make it a Vulcan Locker?😂

[@ProjectDanH]

Lmao! I guess I could have but my Poo doesn't off-road much.. he used it to travel for ski trips

[@shooter77us]

Doing a lot of extra work and doing other things the hard way.

[@ProjectDanH]

Above and beyond for my pops

[@shooter77us]

@@ProjectDanH good response, still teaching the wrong way.

[@albertobynoe4506]

A.S.A.P.Please

[@timturk6003]

Dan we’ve gone over this brakes are for quitters just use a jake brake

[@ProjectDanH]

LMAO! Can't stop won't stop

[@dandahermitseals5582]

You coulda got a Dana 44 disc brake axle off a Ford explorer. Instead pissing in the wind with a Dana 30. Haha. Better luck next time Dandahermit

[@915Performance]

Dana 30? I see a Chrystler 8.25 not a 30

[@robpgreat5724]

brah.... its called lubelocker gaskets

[@ProjectDanH]

RTV forever! LMAO

[@lasagnajohn]

Mods are almost always dumb, this is no exception. Drum brakes have advantages, especially in the rear and especially on an XJ. In the rear, you don't get the fade you get in the front because the harder you brake, the more weight transfer to the front there is. Drum brakes look heavy but they are actually much lighter. Shoes have much larger contact area than pads and more material. Drums don't warp from getting dunked in a creek while super hot. Drums and their lines are well sealed and better positioned. Having a mix gives you the advantages of both, you don't notice it because of the brake booster but drums and discs have quite different performance at different speeds with drums being better at lower speeds. Only race cars should have rear discs. but, because people are stupid: what they do on race cars will trickle down. I got another one for you: A tire simply being wider doesn't mean it will grip better, only a higher mu will do that. But that doesn't matter anyway because if all you do is put on stickier rubber, the result will be that your suspension will be out of it's ideal geometry at the limit of traction. Mods are dumb, even the little ones, even when they're popular, even when they look, sound, feel cool. You know what's apparently not popular? Doing your homework.

[@stevenwebb2295]

😂 Have you ever seen what a drum brake set up looks like after playing in the mud for a weekend? Try it and see how clogged up they get. You'll be putting disc brakes on yours too! The mud is so bad, the competition buggies only put discs on the driveshafts. There is at least one good reason for every mod or it wouldn't have ever been tried to begin with.

[@ProjectDanH]

The XJs successor's have disc brakes... WJ .. ZJ... WHY??? I cant take people who defend drum brakes seriously.

[@BrokenSmokinSpokes]

The only thing "dumb" I can see here is this extra chromosome comment... loool

[@StandAloneAdventures]

Hi Dan, just now seeing this video and was wondering will the 15” wheels work with this conversion, I’ve got all my parts from a 2005 Liberty and haven’t seen where anyone has asked this question or any videos on this showing what wheels will work and what wheels don’t. Thanks for any help with this question

[@ProjectDanH]

Yes, They Should work with factory 15s

[@StandAloneAdventures]

When changing the proportioning valve after doing the Liberty conversion should I use just the Liberty Spring or both the spring and valve from the Liberty?

[@ProjectDanH]

Good question... im not sure the proportion valves are compatable.. if so, use the liberty, however you may need a ZJ disc prop valve