So I finally got around to doing the rear disc conversion on my 93 XJ. I got a set of rotors and calipers/caliper brackets from a dana 35 from a 1998 ZJ. I got them at my local pull your parts and I think I paid $60 bucks for the whole shabang.  I spotted a clean CFC 2002 but the bolt pattern looked much bigger than my 5 on 4.50 so I passed that one up. Anyways so I actually took some picts and have some notes so if anyone else wants to do this too they can. I usually don't do these kind of DIY posts but I had some time and so here it is. The first pic is of the stock rear drum that came on all 8.25 XJ and I believe that my drums are wider because I have the factory tow package. the second and thrid picts are of after I removed the diff cover. The first thing you need to do is remove the screw that holds the cross pin in and then rotate the carrier till the cross pin can be removed.  Now you will need to remove the "C" clip that holds your axles on. Now the entire axle can be removed. The next pic is of the bare axle stub after removing the brake backing plate. Besides the factory axle studs that hold on the backing plate being too short I also opted to upgrade then while I was in there. I used grade 8, 1 inch long, 3/8 diameter bolts I got from my local fastenal. I think I got a bag of 100 bolts, washers and nuts for like $25. Fastenal is my new favorite store. Since the 8.25 is so much stronger than the dana 35 it has thicker axle tubes. I had to make use of my dye grinder and my vice to enlarge the hole about 1/8 inch. Anyways the next slide is of the backing plate/caliper hanger for the disc brake setup bolted on using my new hardware. I actually painted over the rust because really who cares this is not a show vehicle and it will rust again anyways so I just painted it with some rustoleum gloss black and bolted it in place.  The next pic shows the assembly in its new home. I didn't bother with cleaning the rust off the rotor either. The brake pads do this more efficiently. I used the stock brake lines and all I had to do was bend it 90 degrees and attached it to the caliper hose. I drilled a hole in my leaf spring upper plate and bolted the rubber line on top to hold it in place.  I opted not to hook up the park brake either because mine is an automatic and the puny shoes that they call a park brake are an absolute joke and not worth the extra affort. They were removed indefinately and tossed in the junk pile with rest of my old parts.  The last pic is a view from the rear showing that there is still plenty of clearance between the leafs and the calipers. After a few fast stops I went over the the vacant industrial park near my house and got up to 50 and stomped on the brakes at the precise moment when I passed a sign so I could measure how fast I stopped. From 50 I stopped in 82 feet! Less than half the distance needed when my vehicle was stock.  My tires didn't even lock up so that is good to know incase of a panic stop.  Now I just need to figure out how to get more fluid to the rear. I plan on using a new MC but the few ideas I found on other forums require way too much modification to my stock lines. I was thinking about using one from an Explorer but not too sure. I was told the stock ZJ one won't work at all so don't even bother. Anyone got any suggestions???? Also if anyone wants my stock stuff you can have it.

-- Edited by tjhawk on Sunday 27th of June 2010 10:38:21 PM