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.
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.
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!
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.
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!
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 😎
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!
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 👍
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.
@casualactivities1229 yeah i just used the studs for the front on mine and they fit right into the hub perfectly and are long enough although i did use the brakes off a liberty so i dont think the zj brakes are any different but they might be
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!
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?
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
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 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!
@@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
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.
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.
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...
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 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.
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.
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.
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 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!🤔
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?😂
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
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.
😂 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.
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?
![Jeep Cherokee: Rear Disc Brake Swap - KJ/ZJ No Welding; Bolt-on Conversion ['91-'01 XJ]](/img/n.gif)
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.
Hahahahaha! Oh well!
Yes the black plug is the overfill valve. Great video
It's finally here! 🙌🙌🙌🙌🙌🙌🙌🙌
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.
Thanks brother! Yes there's definitely a bunch of other parts that can be utilized for completely custom swaps!
Ive been waiting for this video forever😅🙌
LOL, Me too Brother, Meeee toooo!
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!
That is a really clean, oem looking conversion. Great job Dan!
Thanks Brother! If your gonna do it... Do it clean!!!
Great job Dan. keep it up. God bless you and your family.
Thanks brother, you too!
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.
Thanks Andrew!!! I was wondering why the new cover took so much oil! Haha mine didn't come with any instructions! Lol 🤷
Already have conversion on my 97' but watched your video anyway. Great work!
Thanks brother!
Learning that 13mm trick to remove the parking brake cables was the best part of this video...lol. Great info on the swap - thank you!
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!
Awesome, thank you! I appreciate your kind words and maybe one day you can join the Jeep struggle too!! lol
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.
Haha! Go for it!
@@ProjectDanH What was that kit that you mentioned earlier in the video for the disk brake conversion can you please link it???
Great attention to detail, the WreckedJ looks amazing Dan! 👌🏼
Thanks Brother! Sure did come along way
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 ✌️
Thanks brother!
Awesomeness! Thank You for showing us the way!
My pleasure brother!
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 😎
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!
@@ProjectDanH we will need a video of the lifted Commander for sure !!
geeeaaat job, pal - helpful and entertaining as always !
Lol. Thanks bro!
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 👍
Thanks bro!
Nice Vid~ First Time Viewer!
Thanks you!
Love and appreciate your how to videos
I appreciate that!
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.
Good idea
@@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!
Niiiice job Dan she looks awesome 👍🏾😁
Thank you!!
Good Vid Dan, Now I know how to do it 🖒🖒
Thanks brother!
With the studs on the backing plate! You can also use the studs from the front of the xj
Any stud that's longer. Lol!
Didn’t know that will try tomorrow instead of buying grade 8 bolts or going back to the junkyard to hit them out
@casualactivities1229 yeah i just used the studs for the front on mine and they fit right into the hub perfectly and are long enough although i did use the brakes off a liberty so i dont think the zj brakes are any different but they might be
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!
Yes, you will have to cut the notch! Looks like you'll be conquering it sooner than me. let me know how it goes!!!
So sick!!!
Thanks!
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?
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
@@ProjectDanH Got it, thanks.
First time seeing your video, great job, but I would have torqued down the diff cover .
Thanks man!
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.
Yes, adjust the cable is the worst. Lol . Then once you dial it in they stretch! Haha. Maybe I'll get explorer cables later
@@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!
the bracket you welded for the brake line will that get hit when you go off road? looks to close to the ground
Its possible but we don't off road this jeep. It could be mounted higher for off road use
I never understand the portion valve and changing the spring. What exactly does it do using the ZJ spring?
It portions less fluid to the rear so the disc brakes wont lock up.. rear skidding is bad
@@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?
@@ky0611 only if your rear brakes are locking up
@@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
Great video! Thank you
You are welcome!
Excellent video!
Thank you!
Great video I’ll be doing mine soon I’m gonna get a jeep liberty rear axle any tips I should look forward to ?
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.
LoL. I didn't have an extra 8.8
@@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.
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
Thank you! I bought the rough country N3 shocks from their kit
Thanks again
Nice job Dan, aren’t you worried about the brake line running under the axle, something my snag it and good bye brakes……
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.
Thanks for Watching!!!! the cables work fine, but without a big lift you'll have to rout them where they wont interfere.
youtube.com/@jeepdiscbrake8329?feature=shared
I have no abs and a Dana 35, not the 8.25 Chrysler. Would this work on m my 96 sport?
yes absolutely
@@ProjectDanH,
Thanks for the answer as that is what I also have, a 1996 Jeep Cherokee Sport.
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...
Hey! Great eye! Sometimes I overlook little things while filming.. it happens 🤷
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
4 hole injectors are great. I've done this in all my XJs!
@@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.
Which proportioning valve do u recommend when upgrading to rear disk.
nice job .. FOREVER JEEP.. OIIIIIIIO
#ShawnMrFixitlee you meant Forever JEEP []IIIIIII[] 😆
@@MacsSpecialitiesMotorsportsOld or new it's all good in a Jeep !👍
@@shawnmrfixitlee6478 you got that right!
Thanks bro
Great video and good job 👍 Is there a conversion possible that’s reusing the abs?
Greetings from the Netherlands🇾🇪
Hey will do a similar job for someone else.??
sure
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.
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.
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.
I use both por15 and Rust-Oleum 😁
@@ProjectDanH Thanks Dan I will upload a picture of my XJ once its completed
Great video ✅
What about the e brake hookup! What comes from the drums to the e brake cables.
I used KJ cables
Great informative video 🦾😎
Are you using wheel spacers the the stock wheels ?
no spacers needed
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 #?
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.
@@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!🤔
good
Thank you
I would never hang brake lines under a axle tube if it gets hung up on anything while trailing good luck
Not trail this one, but thanks for the input!
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?😂
Lmao! I guess I could have but my Poo doesn't off-road much.. he used it to travel for ski trips
Doing a lot of extra work and doing other things the hard way.
Above and beyond for my pops
@@ProjectDanH good response, still teaching the wrong way.
Dan we’ve gone over this brakes are for quitters just use a jake brake
LMAO! Can't stop won't stop
A.S.A.P.Please
Way too much fluid.That is what the middle plug is for fluid level
lol.. Thought so!!! haha
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
Yes, They Should work with factory 15s
brah.... its called lubelocker gaskets
RTV forever! LMAO
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
Dana 30? I see a Chrystler 8.25 not a 30
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.
😂 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.
The XJs successor's have disc brakes... WJ .. ZJ... WHY??? I cant take people who defend drum brakes seriously.
The only thing "dumb" I can see here is this extra chromosome comment... loool
This video is not what you should be watching if you think drum brakes are better
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?
Good question... im not sure the proportion valves are compatable.. if so, use the liberty, however you may need a ZJ disc prop valve