XJ Disk Conversion D44

[OnyxGrizzly]

I am going to attempt a rear disk conversion on an XJ D44. I have found a few write ups so far and I really like the detail of this one. I like the fact it still uses jeep parts, which I can get my hands on easier than other parts. I am just curious to see if there is some easier or improved ways of doing it.

http://www.billavista.com/Tech/Articles/Dana_44_Rear_Axle_Disc_Brake_Conversion/index.html

Thanks

Marshall

[Bnine]

No, thats how you have to do it.

You can use Rubicon retainer plates to avoid the sperate spacer, but you have to weld and dill those as well because of the oddball pattern.

Of you can spend big money and order an enire tereflex kit...........

[OnyxGrizzly]

Thanks, and no kit for me 

[apeman]

The explorer 8.8 disc swap is also very popular and pretty easy to do, since the oddball holes are a closer match.

[dubbleJs]

Did you end up doing the conversion? I need to do this on my XJ d44, I have ZJ d44A brake components sitting in the garage.

Will a dealership be ale to pull up "TJ retainer plates" easily?

Is that the only extra part I will need?

On top of getting that retainer plate, drilling the holes to match and boring out the center hole is there anything else?

My drum just starting leaking and I need to get this conversion done quick before a moab trip.............

[EEP]

Jonas,
  I just did this on my XJ (well broken axle did it), from what I know you need to enlarge the retainer hole. The other PIA is finding e.brake cables. Tried a few different ones, finally ordered the terra flex ones. Talk to Eric at broken axle.

[Bnine]

For a better fit they the holes should be filled with weld, ground flush, marked, and drilled.

Two of the holes line up. Two dont

Fill the holes that dont line up with weld and grind them flush

Punch those studs out of the axle housing

Bolt on the backing plate using the holes and studs that fit

Mark the holes that need drilling.

Drill out the holes.

Repeat the process with the 03 and up TJ/Rubicon retaining plates.

Re-install housing studs and bolt everything up.

I would be concerned with just wallowing out the holes, and personally isnt something I'd do. That basically leaves 2 bolts doing the work of 4 as far as holding the backing plate in place goes.

Im sure maybe it might be just fine, but its not what I would do.

Just my 2 cents.

[BrokenAxle]

Just throwing it out there that i have a teraflex kit minus the ebrake cables sitting at the shop that i will let go pretty cheap, relatively speaking.
no welding, grinding or tracking down retainers.... 

[dubbleJs]

After many hours of boring holes and redrilling, and getting the TJ rubi plates onto my shafts I got the pass side bolted on and ready to go, then ran into issues with the driver side. The 4 holes I had drilled offset the center hole just a little bit too much and the axle seal and shaft would not seat, even after boring it out a bit more. I then tried the 'weld the holes up and redrill' trick but that was the end of it. My welds were rock hard and no drill bit in my garage would barely break the surface 
I decided to cut my losses and do this right......I headed down to Broken axle and grabbed the teraflex kit so I could have this done and focus back onto my exo cage..... Thanks Dave! 

[dubbleJs]

Oh and one thing I learned, the ZJ dana44A backing plates are no good. None of the holes line up. You need ZJ dana35 plates.