Rear Disc Conversion

This page is a step by step instruction based on how I converted my rear brakes to discs. 

Index

Parts List
Tools List
Supplies List
Instructions

Parts List

The first step is to collect all the necessary parts.  The table is a list of parts I used in my swap.  I put together all the parts from scratch from various sources.  TSM has a kit that comes with the brackets, rotors, hardware and calipers if you wish.

Tool List

Instructions

1. Jack up the rear end of the Cruiser and place jack stands under the axle
2. Remove the wheels and drums.
3. Remove the brake lines from the wheel cylinders.
4. Remove the brake shoes and springs
5. Remove the six nuts that hole the backing plate to the axle housing.
6. Carefully cut the backing plate so that it can be removed from the axle using a torch or take the open up the differential and remove the axle shafts so the backing plates can be removed.  NOTE:  If you decide to use slightly longer wheel studs you will need to remove the axles anyway to change out the studs.
   
7. Clean the mounting flange on the axle with a wire brush
8. Using four 3/8 bolts or the metric equivalent bolt the caliper mounting plates to the axle flanges.  Be sure to place the ????? washers between the flange and the mounting plate.  The mounting plate goes on the differential side of the flange.
   
9. Check the calipers for fit in the mounting bracket.   Chances are you will have to grind a small amount of material off the caliper where one of the ribs sticks up.
10. Place the rotor on the wheel studs and hold it in place temperarily with a couple lug nuts. 
11. Install the caliper using the two long stud bolts.
    
12. Now turn your attention to the lines.  Attach the flex line to the caliper with the banjo bolt and determine where the other end needs to set making sure the line does not interfere with the spring or shock.
13. Weld a small bracket bracket to the axle housing to hold the other end of the flex line.  Use a c-clip to hold the flex line in the bracket. 
14. In order to complete the brake lines using the existing brake tee on the axle you must make a new line and install a metric fitting on the tee end.  I did my own flaring and it took a fair amount of practice to get the flares to come out correctly.
15. Install proportioning valve in a convienient place along the rear brake line (before it gets to the tee). 
    
16. Remove the residual pressure valve from the master cylinder or with some cruisers in the tee below the master cylinder. 
17. Install the wheels.
18. Bleed the brakes and carefully test their operation.

Warning:  A proportioning valve is not optional with this installation!  The rear calipers are stronger than stock toyota front calipers.   This creates a hazard under emergency braking and braking on surfaces with little traction (snow, ice, dirt roads, etc).  The rear brakes will lock up first and cause your cruiser to become unstable!  A proportioning valve must be installed and adjusted so the front brakes lock up before the rear brakes.  For 4 wheeling you can adjust the valve to give the rear more braking force but remember to adjust it back.

Sources:

TILTON TECHNOLOGIES   FJ40 Disk Brake Conversion

Jack Rice's   Rear Disc Brake Conversion

Bill Jackson makes the caliper brackets. 

I would also like to thank Roy Bates for his machine shop services modifying the inside diameter of the rotors.

Last Updated:  02/16/09
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