This is by far the best and most in-depth video on the XJ disc brake conversion!! I really appreciate you going through the time to make this video so thorough! Thanks Dan!
I was just looking at the rears on my XJ yesterday and found this video this morning. It's really informative. I wondered about the prop valve because the guy who used to do most of my work would have made it sound too hard for me to do. I've been doing ok over the last two years. Thanks for uploading it Dan...
Man what a beauty! Just a wonderful video and this upgrade is a must when you are daily using your xj. Man but abs is just the cherry in that upgrade! Just amazing Dan!
Most of my friends made me feel like a psycho for busting out a wire wheel on my wheel hub assembly while replacing my ball joints (front). I even painted the knuckle with anti rust afterwards! Good goin', man. Love your content, dude.
Awesome video!! I have had so many headaches trying to work out some of the issues Dan has explained clearly here i.e. parking brake cables and the ABS. Everything Jeep can be so difficult in the UK with RHD and a paucity of Jeeps in breakers' yards. Thank you America!
Well that's interesting! I did this conversion on my 1998 XJ 4.0 Ltd and the parking brake has been just, I mean only just, good enough to get through a UK MOT test, which only requires 16% efficiency. I used all new parts. The interesting bit for me is how you put the actuating lever on top of the slide instead of the usual way of having the sliding bit at the top. Trying to work out why the parking brake for a car bigger than a XJ is so useless, I found the lever tries to twist when pulling the handbrake lever. Hopefully turning it upside down will cure that and hopefull make it better. I'm taking it apart tomorrow, we'll see... Great video, well filmed and good clear instructions.
I love everything that your doing, just wanted to make a small note to all the world, crc black brake grease will eat all plastics/silicones it contacts. It is really only good for use on the pad tabs/rattle hardware. Permatex Purple brake grease ftw!
@@ProjectDanH So did I... once. lol 😂 oops. You are awesome, just started making a 3 row xj for family transport. Bought 1 perfect rust free with a bad engine, the other has a good running engine, a backseat, and about nothing else. Wish me luck 🤞 and Happy 2024! Thank you for your wealth of jeep recources!
Awesome content! Welcome back and hope you and your family are well!! I’m slowly amassing the parts to do this same swap with KJ parts onto my 98 XJ! If you’re ever in Queens I’m gonna put you to work helping me with the swap! :D
Im doing the KJ swap as well, on my 93 XJ. Waiting for the parts to finish coming in, but the Pick N Pull nearest me (Tacoma, WA) had no less than 5 KJs untouched on rear disc brakes, and at least 4 ZJs to pull soft brake hose and proportioning valve from. Makes me feel sorry for all the posts on forums about junkyards in other states having deficit of either.
@@ProjectDanH Not completely sure of fitment, but Crown makes the parking lever boots for 2002-2008 KJs, and it looks identical to the shape of one for ZJ. Crown 5093395AA. Got them for $10 each at Morris 4 x4. If they are match, then no need to buy TJ ones and trim the top off (though thats obviously an easy mod). :)
Hey Dan, tomorrow morning they will bring me the diff of the zj to my garage, I hope I can do the job without problems and tell you that everything went Ok , soon, I would like to restore all before do the job.......from Argentina, Rolf
Great video, appreciate the detail! It made me wonder if something similar is possible on my Sportage. I am definitely going to be brainstorming for the next few weeks.
You can get everything but the proportioning valve from the '02-05 KJ Liberty. Same Corporate 8.25 axle housing with coils, discs, 29 spline shafts and axle gears. No mods to the backing plate as it already fits 8.25 but still need longer bolts. Crown Automotive has the parking brake cables for the conversion too.
@@ProjectDanH Ive seen some DIYs that say the brake cables from 1995-2001 Ford Explorer are drop in fit for stock XJ, as well. I went with KJ ones to start, but if they take major mod to work on stock, then I'll try the Explorer ones.
@@ProjectDanH I just found out about these, made by Crown for their disc brake conversion kit, but think they will work for liberty or Grand Cherokee as conversion also. They are only for 1991-1996 without ABS, but they also are only 1 inch shorter than drum brake cable - probably because lever for disc is on top of backing plate, but drum has it on bottom. This wouldnt work for people with lift, but for stock or little lift XJ, would work beautifully. Has all the right connectors, so no mod to cable needed. www.quadratec.com/p/crown-automotive/rear-parking-brake-cable--xj-disc-brake-conversion-rt31039
For the first 20 minutes I was going, I hope he talks about the lug studs, I hope he talks about the lug studs. When I did my conversion I the KJ swap because the backing plates bolted on my 8.25 with no grinding. Should have used ZJ hoses though. I've always had the best luck with Crown Automotive parts. They used to make disc brake conversion parking brake cables for the XJ, but that was a couple years ago, don't know if they still do. I thought the KJ cables were longer, but I went a different route and ended up removing the parking brake shoes. Good job on the video, been too long since I saw one.
Thanks man! I actually mentioned the conversion cables but edited them out because they're always out of stock when I look. I didn't want to waste anyone's time, the video was long enough 🤣
Hey Dan, did you ever do a video of you installing these ZJ rear disc brakes with abs on your XJ? Or are you waiting for your special beach jeep to install them on. Great videos Dan you do good work. ✌🏻
No I didn't get to install the conversion yet.. I got to get the wreck Jay off my slab so I can take care of the job the right way 👍 sorry for taking so long!
Great video! This video was so helpful! Thanks for making it! I pulled all my parts yesterday from the local wrecking yard. I was unable to find rear brake hoses, but luckily found everything else. I noticed on the previous video you pulled the brake hoses and didn't replace them, but pretty much replaced everything else. Just wondering why or did you replace the hoses too and not include it in the video. Assuming you don't have a video of the finished install?
I havnt gotten around to the conversion yet! lol. sorry I've been slacking. lol In my past conversions I have just attached the ZJ disc softline to the XJ drum hardline. should thread right on.
Banjo fitting "raised" part I believe was installed improperly. The "raised" part should go against the caliper. I think its there to prevent rotation of the fitting thus preventing loosening of the fitting. Correct me if Im wrong....
If they're used they should be reinstalled exactly the way they were removed.. when they are new it shouldn't matter because they will crush and form fit into place.
Now kick question, I’m planning on putting 17x9 rims and 35 inch tires I may need other type of calipers fort this conversion and if this disk plate would hold other caliper more bigger than the actual, or if this set up will work on my built
excuse my ignorance but the rear discs from a 1999 zj can be used in a jeep xj. I ask because everywhere I see that they use the rear discs of zj 1998 not those of the zj 1999 ?
I'm not sure but if you buy new calipers they come with new bolts.. Maybe you could go to the parts store and ask him if you can peak into the box to size up the bolt
Hi Dan, almost finished the job but.... Are you sure that the parking brake cable driver side is correct? I've ordered it at Rockauto and the length is the same as the cable for the passenger side. Double checked it and numbers are correct but the cable is way too long.. Regards Arjan
It's been a while Dan, but my babies running great 👍. I'm using the Texaco oil and add zinc if I hear 👂 a sharp tink, once or twice a year. I'm still spreading the word on other oils 🛢 I'm going to check a ZJ and wanted to confirm what years have rear disk, brake master,as much of the front end that fits, fuel injectors, for my stock 92' XJ. Am I forgetting anything else important ?
Good stuff brother! I think disc brakes were found on limited models from 1993 to 1995 and then rear disc brakes were standard on all ZJ's 96 to 98... I think
@@ProjectDanH Nice! Have had most of the parts sitting in my garage for like 4 years now lol need some odds and ends, ebrake cables, porp valve, and to see about if I need the longer studs, I'm using steel wheels
Hey Dan, So for the ABS.. can the tone rings off the dana 35 axle shafts can be swapped to the axle shafts of a 8.25? Or do you just swap the entire shaft from d35 into 8.25? Are the shafts interchangeable between the two axles?
Really appreciate this video I was concerned about the rubber boot and where to find a replacement. then the fun task on how to piece it all back together with the E brake arms. Thanks for the detailed info! As for the proportioning valve can I use the stock XJ threaded end that screws back into the combination valve? I didn’t grab the one off the ZJ, just the internals. I just as well assumed the screw cap was the same size as the one on the XJ and wasn’t of any importance. All other parts for my disc swap are coming from a KJ for my 8.25 axle. Thanks! Keep on jeepin on life’s a garden dig it 🤙🏾
Mineral spirits- no gloves Brake fluid- no gloves etching - gloves only for oil on his hands I've been wanting to do this project for a while now thanks for the walkthrough
Sure, but anything you find in the junkyard will probably need a rebuild anyway. Its also easier to take the backing plates off a ZJ rather than to cut off the coil spring perches and weld on leaf spring mounts.
Great Video! will be doing this upgrade soon...luckily, I have several rust free ZJ's available near me for parts. Aren't you concerned that as your breaks wear, all the brake dust will gunk up your breaks with all that grease?
If you use the WJ front brakes with the ZJ rear disc, how is the brake bias? The stock XJ brake bias is pretty much all fronts, and I find that to be a problem especially when you have some hitch tongue weight.
Think you might be the guy i want to talk to about this, have backing plates and shields i scored on NAXJA...is the process the same on the corporate 8.25 axle in a 99? If i’m ordering new ZJ parts, do i need for the 4.0 or the V8? Side note: i think i’ve run into you and the rest of the crew once or twice at Harrys 🤣
all ZJ rear disc brakes are the same regardless of 4.0 or 5.2. you can order ZJ pads rotors parking brake hardware and KJ liberty parking brake cables . If your putting ZJ backing plates on a C8.25 you will have to do a little grinding on the plates to enlarge the axle tube holes. if you don't want to grind anything you can just get KJ parts. good luck!
@@ProjectDanH thanks Dan👍🏻 i dont mind grinding, its a Heep ;) just wanted to verify before i order, none of the forums mention the v8 used the same rear brakes as the 4.0. pricing out all the extras its around $450 for new/reman parts thru rock auto (and local for chems/hardware). Not bad considering, and thats about the cost of an average brake job anymore.
Any ZJ w/ rear discs will work, however you will have to dremel out some of the inside of the plate to accommodate the larger diameter axle tube. You may want to look for a KJ liberty rear disc setup. They had 8.25 rears. Then you won't have to grind any metal
Really appreciate this video on Prep. I'm doing KJ to XJ, but same things apply for cleaning and painting, etc. My POR15 caliper paint kit just came in,to paint store, so can get it tomorrow. I didn't have tumbler, but Locktite Naval Jelly and wire brush did nice job cleaning up hardware. I was curious why you used the caliper paint directly to metal: POR15 recommends putting the base rust sealing paint on, and then top coating that with the caliper paint. Is the base POR15 not really needed (aka they want you to buy more product and use it)?
thanks Andrew I really appreciate the view. regular pore 15 isn't rated for heat so I figured it would crumble off with the caliper paint on top of it so I just bypassed the regular por15 and went straight to the caliper paint. it worked really well sticking to the metal directly but a lot of the places with spilt brake fluid lifted some of the paint. I guess only time will tell if it holds up
@@ProjectDanH I found out that there is a High Temp POR15 rust sealer that's rated up to 1200 degrees Fahrenheit. I still used the regular stuff and then caliper paint on top, and will see how it holds up, but if it shows issues, will give the high temp stuff a try with caliper paint on top. Will also watch to hear how just using caliper paint works, too. Always good to learn different ways of doing things, so thank you.
I dont believe it makes a difference with the XJs (will need to check) but wont you have to change out the Master Cylinder to accommodate ABS? Always a great video Dan., keep the ZJ going. I just got another 98 for a project car with my trail rig
I didn’t watch the whole thing yet because I’m at work and you probably answered this, but what would be the added advantage of doing this to my XJ? Is there a significant difference?
Hey Dan I just subscribed to your channel as I'm enjoying your content. I don't have an XJ (yet ) I have a 03 TJ 4.0 , 42 RLE Trans . I have been wanting to do rear disc brakes on it and wondering if this could apply to the TJ also . The kits they have out there are quite expensive and I thought this would be a great alternative. Also we have two wrecking yards near by and both of them have a abundance of ZJ's to chose from . What year of ZJ would I use as the donor ? Thanks for your help in advance. Take care and be safe.
@@ProjectDanH I have the Dana 35. Its actually a super 35. 30 spline axles, E locker etc. I wasn't sure what to do for e brake cables then it dawned on me that Rubicon TJs had rear disc so that turned out to be a winner. Lol
why didnt you wirebrush the dust cover / backing plate and other rusty parts as well instead of going over the rust with paint? i get it that paint is supposed to bond because of the primer prep but whynot go ahead and get all the rust off? was it to save time? not criticizing your methods just genuinely want to know ! O and Thx for your effort Dan! Very helpful and informative!
![Jeep Cherokee: Rear Disc Brake Swap - KJ/ZJ No Welding; Bolt-on Conversion ['91-'01 XJ]](http://i.ytimg.com/vi/hoSTNrbwCAk/mqdefault.jpg)
This video and the parts list in the description is a God send. Thanks Dan!
your welcome!
I have watcjhed a ton of videos on this swap and this is the best Danno. Complete without a bunch of useless shots
thanks dude.. so much info to unpack, hope its not too choppy.
This is by far the best and most in-depth video on the XJ disc brake conversion!! I really appreciate you going through the time to make this video so thorough! Thanks Dan!
I appreciate that! I'm glad you enjoyed it!
Ready for the conversion vid???
I’m I’m in 😀😀😀
Damn... Best car repair video on TH-cam so far.. Keep it up!
Haha! I actually have to do the brake swap now!
I was just looking at the rears on my XJ yesterday and found this video this morning. It's really informative. I wondered about the prop valve because the guy who used to do most of my work would have made it sound too hard for me to do. I've been doing ok over the last two years. Thanks for uploading it Dan...
Glad I could help! prop valve is simple,. bleeding the entire system is the worst part. lol
THE KING HAS RETURNED!, hope all is well and the family is good, great work as always
Thank you James! We are blessed and well. It's good to be back 💪
Dan the man at it again! Thank you for this video!
Thank you !! More to come!
Man what a beauty! Just a wonderful video and this upgrade is a must when you are daily using your xj. Man but abs is just the cherry in that upgrade! Just amazing Dan!
Thank you so much Jose! Yes, I can't wait to get it all installed 😃
Great video! Thanks!!
You had me concerned about the 'grease', until you mentioned NY.
Agreed, it is better than the rust!!!
Lol! Thanks Papa Mac! I appreciate your view 👍
Most of my friends made me feel like a psycho for busting out a wire wheel on my wheel hub assembly while replacing my ball joints (front). I even painted the knuckle with anti rust afterwards! Good goin', man. Love your content, dude.
No way man, Keep it Clean and fresh... youl be the one with the last laugh when your rig is still on the road 30 years later!
very clear tutorial...we are sure the brake will work smoothly...excelent ! regards richard,xj lover indonesia.
Glad it helped! thanks for watching!
Primo stuff Danno! I have always wanted to do this to an XJ
every XJ needs this! (except for police models with 9" rear drums... they're unique) 🤣🤣🤣
Awesome man. I’ll definitely come back to this when I rebuild brakes and forget where something goes. Great content 👍👍
haha! thanks man... me too! 🤣
Awesome video! Very very thorough! Will have my swap done next week! Super excited to have rear discs. Thanks for sharing all the info! ❤️🐞
Thanks bug!! I love rear discs! Can't wait to see your Jeep and house complete! 😃😃🍦🍦
This is so great for a Friday night… so much better than the Winter Olympics…
LMAO ... china SMH . lol
@@ProjectDanH exactly…
Great job keep it up 👍🏻 TEN THOUSAND HERE WE COME !!!
Yes! Thank you buddy, much appreciated! I see you got your YT account Back! 🤣
Awesome video!! I have had so many headaches trying to work out some of the issues Dan has explained clearly here i.e. parking brake cables and the ABS. Everything Jeep can be so difficult in the UK with RHD and a paucity of Jeeps in breakers' yards. Thank you America!
thank you so much, I'm glad my vids are able to help😁
Thanks for this! I've been parting out Jeep after Jeep stocking up parts. Going to do this swap on my XJ
You're welcome! Sounds like you have a parts pile like me 🤣
Great job glad to see you back at the videos
Thanks! more to come 👍👍
Just Did this to my xj 2 months ago and it’s amazing
awesome Brandon, glad to hear! hope you and the family are doing well. 💪
WOW, detailed with a capital "D". Nice vid. Dying to see the project continue. Have a great labor day weekend.
Thanks brother! To be continued 😃
you should have 50000 subs...you have a cool channel
Thanks man. Share and spread the word!
Awesome job Dano! Congratulations on 10K subs.Man I love your attention to detail.The beard is looking good too buddy....
Thanks so much Dan! You've been here since Day1! I appreciate the love!
Well that's interesting! I did this conversion on my 1998 XJ 4.0 Ltd and the parking brake has been just, I mean only just, good enough to get through a UK MOT test, which only requires 16% efficiency. I used all new parts. The interesting bit for me is how you put the actuating lever on top of the slide instead of the usual way of having the sliding bit at the top. Trying to work out why the parking brake for a car bigger than a XJ is so useless, I found the lever tries to twist when pulling the handbrake lever. Hopefully turning it upside down will cure that and hopefull make it better. I'm taking it apart tomorrow, we'll see...
Great video, well filmed and good clear instructions.
Thanks man! Best wishes.. keep me updated
I love everything that your doing, just wanted to make a small note to all the world, crc black brake grease will eat all plastics/silicones it contacts. It is really only good for use on the pad tabs/rattle hardware. Permatex Purple brake grease ftw!
Oh man... Thanks for the tip.. I figured it was safe for all brake parts! 🤦
@@ProjectDanH So did I... once. lol 😂 oops. You are awesome, just started making a 3 row xj for family transport. Bought 1 perfect rust free with a bad engine, the other has a good running engine, a backseat, and about nothing else. Wish me luck 🤞 and Happy 2024! Thank you for your wealth of jeep recources!
Lots of how to information . 👍🏻Great Video Dan. ✅🇺🇸
Glad you enjoyed it!
I don't have a Xj but im still watching lol
lol, Thanks! I imagine its similar for most vehicles.
Awesome content! Welcome back and hope you and your family are well!!
I’m slowly amassing the parts to do this same swap with KJ parts onto my 98 XJ! If you’re ever in Queens I’m gonna put you to work helping me with the swap! :D
Lol! Sure buddy! KJ swap is perfect for a C8.25 axle 👍
Im doing the KJ swap as well, on my 93 XJ. Waiting for the parts to finish coming in, but the Pick N Pull nearest me (Tacoma, WA) had no less than 5 KJs untouched on rear disc brakes, and at least 4 ZJs to pull soft brake hose and proportioning valve from. Makes me feel sorry for all the posts on forums about junkyards in other states having deficit of either.
@@ProjectDanH Not completely sure of fitment, but Crown makes the parking lever boots for 2002-2008 KJs, and it looks identical to the shape of one for ZJ. Crown 5093395AA. Got them for $10 each at Morris 4 x4. If they are match, then no need to buy TJ ones and trim the top off (though thats obviously an easy mod). :)
Good info! Glad you didn't use that homemade setup at 23:32, the cable clamps are installed backwards aka "never saddle a dead horse."
wow, good eye! I didn't even realize I reversed it for the demo. yup always clamp the live end!!!
@@ProjectDanH I only noticed because I was just stringing some cable for outdoor lights and had the dead horse thing on my brain heh.
@@maskedmotorsdiy3575 classic! Thank you 💪
Doing the swap on my 92, 8.25 rear. Thank you for sharing.
Right on, good luck!!
I been wondering if d35 disc brakes will fit on an 8.25. This didnt exactly answer that question.
Love the Pork chops Dan !! lol
🤣🤣🤣🥩
Nice work man!!! Next project for my 99.
Yahoo Buddy! This is always a fun one!
So much great info... I picked up the brackets today from a wrecking yard, but the dust shields were crap.... I'm going to try to find those next.
Awesome!! Hopefully I can get my video out before you do your swap
@@ProjectDanH We'll see... all the parts are, surprisingly enough, in stock and on their way to me...😬
Great video as always. With all the rust removal you do you should setup a electrolysis tub.
Thats a great idea! Ive been wanting to do electrolysis for a while now!
You can also grab the e brakes from a KJ at the junkyard. They just go under the carpet under the center console but super easy to get.
excellent info!
Great video! Thanks for all of the detailed info.
Glad it was helpful!
Look who back , back again 😂
DanH back, tell a friend 🎶🎶🤣🤣🤣
Nice vid, been thinking about doing this to my xj
Thank you! Hopefully I clarified any questions you may have had 😃
Just wanted to share with you on brake parts that are made of rubber use Silicone spray it dry fast but it helps in rubber parts for brakes.
Thanks Ray!
Hey Dan, tomorrow morning they will bring me the diff of the zj to my garage, I hope I can do the job without problems and tell you that everything went Ok , soon, I would like to restore all before do the job.......from Argentina, Rolf
excellent! good luck buddy. God Bless
Great video, appreciate the detail! It made me wonder if something similar is possible on my Sportage. I am definitely going to be brainstorming for the next few weeks.
Thanks man! I'm sure you can manage a swap, anything is possible 💪
You can get everything but the proportioning valve from the '02-05 KJ Liberty. Same Corporate 8.25 axle housing with coils, discs, 29 spline shafts and axle gears. No mods to the backing plate as it already fits 8.25 but still need longer bolts. Crown Automotive has the parking brake cables for the conversion too.
yep I usually recommend a KJ setup for people with Chrysler 8.25s although I did a ZJ set up on my 8.25 as well
Damn... never knew about the KJ liberty e-brake cables
they're a little long for stock, but great for a lifted XJ!
@@ProjectDanH Ive seen some DIYs that say the brake cables from 1995-2001 Ford Explorer are drop in fit for stock XJ, as well. I went with KJ ones to start, but if they take major mod to work on stock, then I'll try the Explorer ones.
@@ProjectDanH I just found out about these, made by Crown for their disc brake conversion kit, but think they will work for liberty or Grand Cherokee as conversion also. They are only for 1991-1996 without ABS, but they also are only 1 inch shorter than drum brake cable - probably because lever for disc is on top of backing plate, but drum has it on bottom. This wouldnt work for people with lift, but for stock or little lift XJ, would work beautifully. Has all the right connectors, so no mod to cable needed. www.quadratec.com/p/crown-automotive/rear-parking-brake-cable--xj-disc-brake-conversion-rt31039
Nice job, thank you!
anytime Chris! thanks for watching!
For the first 20 minutes I was going, I hope he talks about the lug studs, I hope he talks about the lug studs. When I did my conversion I the KJ swap because the backing plates bolted on my 8.25 with no grinding. Should have used ZJ hoses though. I've always had the best luck with Crown Automotive parts. They used to make disc brake conversion parking brake cables for the XJ, but that was a couple years ago, don't know if they still do. I thought the KJ cables were longer, but I went a different route and ended up removing the parking brake shoes. Good job on the video, been too long since I saw one.
Thanks man! I actually mentioned the conversion cables but edited them out because they're always out of stock when I look. I didn't want to waste anyone's time, the video was long enough 🤣
@@ProjectDanH might as well, you never know, I ordered mine directly from Crown, but they might be on Amazon too.
@@robertgrauman8602 I actually ordered them directly from crown for this project but when they never arrived I saw they were back ordered 🤣
@@ProjectDanH gotta love 2020.
Hey Dan, did you ever do a video of you installing these ZJ rear disc brakes with abs on your XJ? Or are you waiting for your special beach jeep to install them on. Great videos Dan you do good work. ✌🏻
No I didn't get to install the conversion yet.. I got to get the wreck Jay off my slab so I can take care of the job the right way 👍 sorry for taking so long!
@@ProjectDanH my dude it’s all good. Nice front WJ seat repair. Look forward to seeing that XJ project on the road.
GREAT PREP VIDEOAm I wring in assuming that you can also do a conversion of dual calipers disc brakes from a WJ?
I've never tried WJ knuckles on an XJ... Yet
Wheel stud is a rear od front axle? Thx 😊
Wheel studs for rear!
Great video! This video was so helpful! Thanks for making it! I pulled all my parts yesterday from the local wrecking yard. I was unable to find rear brake hoses, but luckily found everything else. I noticed on the previous video you pulled the brake hoses and didn't replace them, but pretty much replaced everything else. Just wondering why or did you replace the hoses too and not include it in the video. Assuming you don't have a video of the finished install?
I havnt gotten around to the conversion yet! lol. sorry I've been slacking. lol In my past conversions I have just attached the ZJ disc softline to the XJ drum hardline. should thread right on.
@@ProjectDanH About to do my conversion. You should post yours!
Banjo fitting "raised" part I believe was installed improperly. The "raised" part should go against the caliper. I think its there to prevent rotation of the fitting thus preventing loosening of the fitting. Correct me if Im wrong....
If they're used they should be reinstalled exactly the way they were removed.. when they are new it shouldn't matter because they will crush and form fit into place.
@@ProjectDanH Correction: Just replaced my right rear wheel speed sensor. The the banjo fitting is installed exactly as yours is.
Doing this upgrade soon. My 01 XJ already has abs sensors on the rear. Can I re-use them on the ZJ disc brakes?
no, different type. you cant use the XJ sensors, but the ZJ uses the same connectors that you attach under the rear seats.
On the about 96 and older XJ the e-brake runs down the center also.
Wow, That's good to know. Then maybe 96 and older can re use the ZJ cables!
I bought a pair and they are holding up very well. They have been on my rig for one year.
@@OLDBEAR123456 awesome!
Now kick question, I’m planning on putting 17x9 rims and 35 inch tires I may need other type of calipers fort this conversion and if this disk plate would hold other caliper more bigger than the actual, or if this set up will work on my built
You won't need bigger calipers for the rear.. you may want to consider a WJ knuckle swap for bigger brakes in the front tho
@@ProjectDanH thank u boss, keep up the good work on this XJ series, it has been a great help I’m my XJ project 💯
Did you ever put them on your xj,if so I couldn't find the vid,great job you do
video coming this spring 💪
excuse my ignorance but the rear discs from a 1999 zj can be used in a jeep xj. I ask because everywhere I see that they use the rear discs of zj 1998 not those of the zj 1999 ?
no, 99 grand Cherokees are WJ's
Hello dan! Can you tell me the part number of the screws that hold the caliper to the bracket?
I'm not sure but if you buy new calipers they come with new bolts.. Maybe you could go to the parts store and ask him if you can peak into the box to size up the bolt
Hi Dan, almost finished the job but.... Are you sure that the parking brake cable driver side is correct? I've ordered it at Rockauto and the length is the same as the cable for the passenger side. Double checked it and numbers are correct but the cable is way too long.. Regards Arjan
I use the KJ cables they are long but it's great for Jeeps with a lift.
It's been a while Dan, but my babies running great 👍. I'm using the Texaco oil and add zinc if I hear 👂 a sharp tink, once or twice a year. I'm still spreading the word on other oils 🛢 I'm going to check a ZJ and wanted to confirm what years have rear disk, brake master,as much of the front end that fits, fuel injectors, for my stock 92' XJ.
Am I forgetting anything else important ?
Good stuff brother! I think disc brakes were found on limited models from 1993 to 1995 and then rear disc brakes were standard on all ZJ's 96 to 98... I think
Are you gonna have a video where you install these parts?
Yes! Hopefully this Fall!!
@@ProjectDanH Nice! Have had most of the parts sitting in my garage for like 4 years now lol need some odds and ends, ebrake cables, porp valve, and to see about if I need the longer studs, I'm using steel wheels
Hey Dan,
So for the ABS.. can the tone rings off the dana 35 axle shafts can be swapped to the axle shafts of a 8.25? Or do you just swap the entire shaft from d35 into 8.25? Are the shafts interchangeable between the two axles?
If you have an D35 with abs, you will need the axles and tone ring from a ZJ D35 . You will have to modify the XJ flange to fit the ZJ abs sensor
Dan what year of zj did you get your stuff of and what year is your xj ? I jave a 96 xj so is it easier for me to find a 96 zj to do the swap?
any ZJ with rear disc brakes should work for any XJ
what rear axle is this for? I have a Dana 44 will this work for me?
it's for a d35 or c8.25. not sure what d44 you have but if it's an XJ d44 non c clip you should check out Nick in times swap
Hey ! Great job ! If the zj has a Dana 44, with C look... I have a Dana 35, this works ?? Tks
it should, you may have to grind out the center section a little more nick in time did a good D44 brake vid
Really appreciate this video I was concerned about the rubber boot and where to find a replacement. then the fun task on how to piece it all back together with the E brake arms. Thanks for the detailed info! As for the proportioning valve can I use the stock XJ threaded end that screws back into the combination valve? I didn’t grab the one off the ZJ, just the internals. I just as well assumed the screw cap was the same size as the one on the XJ and wasn’t of any importance. All other parts for my disc swap are coming from a KJ for my 8.25 axle. Thanks! Keep on jeepin on life’s a garden dig it 🤙🏾
thank you so much for watching 💪 yes you have to put the ZJ valve and spring inside your XJ block with your XJ cap. at least that's how I do it. 👍
Can you help me with the size of the backing plate stud? Difficult to find in my country , need diameters of the stud please
What year's or packages, do the ZJ's (grand Cherokee) come with rear disk brakes to swap over 🤔?
1993 to 1995 limiteds and all ZJ's 1996 to 1998... I think
Mineral spirits- no gloves
Brake fluid- no gloves
etching - gloves only for oil on his hands
I've been wanting to do this project for a while now thanks for the walkthrough
Thanks for watching!
Can you put a whole ZJ rear end in an XJ and save all this extra time rebuilding the discs?
Sure, but anything you find in the junkyard will probably need a rebuild anyway. Its also easier to take the backing plates off a ZJ rather than to cut off the coil spring perches and weld on leaf spring mounts.
XJ Cherokee came with at least 3 different rear differentials: D35, Chrysler 8.25, and D44. Which is this for?
Watch the video! D35 and c8.25
I'm assuming like all the others, this works if you have a 8.25 rearend. What if you have a Dana 30C rear end like mine does? Is it still viable?
Great Video! will be doing this upgrade soon...luckily, I have several rust free ZJ's available near me for parts.
Aren't you concerned that as your breaks wear, all the brake dust will gunk up your breaks with all that grease?
Haha, that's a great question.. I'm more concerned with rusted parts so I'll take my chances with the grease. Good luck on your conversion!
Is this for the Chrysler 8.25
it's for both a d35 and a c8.35. you will need to enlarge the diameter of the axle tube hole to fit the backing plate on the c8.25
Is this applicable to a Dana 35?
Absolutely
Will this work on a Dana 35
If you use the WJ front brakes with the ZJ rear disc, how is the brake bias? The stock XJ brake bias is pretty much all fronts, and I find that to be a problem especially when you have some hitch tongue weight.
not sure buddy.. I've never used WJnfront brakes.
These year ZJs are hard to find in my area. Anyone got some other year or models that will swap out as well? Thanks for the vids Project Dan.
Think you might be the guy i want to talk to about this, have backing plates and shields i scored on NAXJA...is the process the same on the corporate 8.25 axle in a 99? If i’m ordering new ZJ parts, do i need for the 4.0 or the V8?
Side note: i think i’ve run into you and the rest of the crew once or twice at Harrys 🤣
all ZJ rear disc brakes are the same regardless of 4.0 or 5.2. you can order ZJ pads rotors parking brake hardware and KJ liberty parking brake cables . If your putting ZJ backing plates on a C8.25 you will have to do a little grinding on the plates to enlarge the axle tube holes. if you don't want to grind anything you can just get KJ parts. good luck!
@@ProjectDanH thanks Dan👍🏻 i dont mind grinding, its a Heep ;) just wanted to verify before i order, none of the forums mention the v8 used the same rear brakes as the 4.0. pricing out all the extras its around $450 for new/reman parts thru rock auto (and local for chems/hardware). Not bad considering, and thats about the cost of an average brake job anymore.
@@Wtfbbq23 sounds like a score! Good luck Buddy!
With this conversion can I be hable to keep using my stock wheels?
absolutely
What year ZJ did you take the brakes off of I have a Chrysler 8.25 without the ABS so which ZJ would be best
Any ZJ w/ rear discs will work, however you will have to dremel out some of the inside of the plate to accommodate the larger diameter axle tube. You may want to look for a KJ liberty rear disc setup. They had 8.25 rears. Then you won't have to grind any metal
Really appreciate this video on Prep. I'm doing KJ to XJ, but same things apply for cleaning and painting, etc. My POR15 caliper paint kit just came in,to paint store, so can get it tomorrow. I didn't have tumbler, but Locktite Naval Jelly and wire brush did nice job cleaning up hardware. I was curious why you used the caliper paint directly to metal: POR15 recommends putting the base rust sealing paint on, and then top coating that with the caliper paint. Is the base POR15 not really needed (aka they want you to buy more product and use it)?
thanks Andrew I really appreciate the view. regular pore 15 isn't rated for heat so I figured it would crumble off with the caliper paint on top of it so I just bypassed the regular por15 and went straight to the caliper paint. it worked really well sticking to the metal directly but a lot of the places with spilt brake fluid lifted some of the paint. I guess only time will tell if it holds up
@@ProjectDanH I found out that there is a High Temp POR15 rust sealer that's rated up to 1200 degrees Fahrenheit. I still used the regular stuff and then caliper paint on top, and will see how it holds up, but if it shows issues, will give the high temp stuff a try with caliper paint on top. Will also watch to hear how just using caliper paint works, too. Always good to learn different ways of doing things, so thank you.
@@gryffydd42 I was also thinking of switching over to Eastwood products
If your XJ has ABS, then you have a Dana 35 rear. If not, you most likely have an 8 1/4". If so KJ disc backing plates are the way to go.
Exactly
How many times can you promote 415
Meh... Im over it! lmao
I dont believe it makes a difference with the XJs (will need to check) but wont you have to change out the Master Cylinder to accommodate ABS?
Always a great video Dan., keep the ZJ going. I just got another 98 for a project car with my trail rig
Thank you so much! Nope you don't have to mess with the master, although I will be doing an Durango master swap too 😃👍
@@ProjectDanH All good then! I got a Durango steering box been on my shelf for a year now. Never enough time to for projects
When Sir? Waiting for 6 months now...
Soon as I get Wreck J outta the way
I didn’t watch the whole thing yet because I’m at work and you probably answered this, but what would be the added advantage of doing this to my XJ? Is there a significant difference?
better braking, easier maintenance
Which junk yard do you go to? I live on long Island too
Hey Danielle! im always picking at Peconic Auto Wreckers in Remsenburg. They're the best!
@@ProjectDanH Thank you!!
Righteous 🤙🏾
AMEN!
What year ZJ parts
and ZJ with disc brakes and a D35
Hey Dan I just subscribed to your channel as I'm enjoying your content. I don't have an XJ (yet ) I have a 03 TJ 4.0 , 42 RLE Trans . I have been wanting to do rear disc brakes on it and wondering if this could apply to the TJ also . The kits they have out there are quite expensive and I thought this would be a great alternative. Also we have two wrecking yards near by and both of them have a abundance of ZJ's to chose from . What year of ZJ would I use as the donor ? Thanks for your help in advance. Take care and be safe.
yes This will definitely work in a TJ.. What rear end do you have?
@@ProjectDanH I have the Dana 35. Its actually a super 35. 30 spline axles, E locker etc. I wasn't sure what to do for e brake cables then it dawned on me that Rubicon TJs had rear disc so that turned out to be a winner. Lol
@@moabwheeling lol! I'd grab a ZJ D35 set up.. should be bolt on! 👍
Does anyone know if an ZJ backing plate will fit a TJ Rubicon Dana 44?
youll most likely have to grind out the center alot
@@ProjectDanH yessir, specifically a tenth of an inch. I used a 3” hole saw to make it perfect
why didnt you wirebrush the dust cover / backing plate and other rusty parts as well instead of going over the rust with paint? i get it that paint is supposed to bond because of the primer prep but whynot go ahead and get all the rust off? was it to save time? not criticizing your methods just genuinely want to know ! O and Thx for your effort Dan! Very helpful and informative!
I cleaned the heck out em! watch at 6:19, 11:20, 11:57 . I never paint anything unless its cleaned and prepped.
If i win the lottery im buying you a blasting cabinet.
Bro! I need one so bad... And a parts cleaning tank!!
@@ProjectDanH And a work shop so your poor wife can keep black beauty nice and warm during the winter.
@@1manmanythings144 oh man! I really pray you win!
Dan H..... I need 2 stickers for my ZJ.....
hit me up on Instagram 💪
When is the disc install video?
soon! I gotta get a couple nice days off.. weather has been killing me.. I need to rake my work space too! Ahhh so busy! lol
Any reason to use ZJ setup over the KJ?
ZJ for the the D30 rear. if I had a C8.25 id be more inclined to use the KJ
@@ProjectDanH makes sense. Thanks.
Ok I'm "special" did you have the whole parts list somewhere?
the video description is where I post everything
Did you really not do an install video?
not yet!
Buy a good quality sandblaster cabinet that has the legs
Thats exactly what I Need!
I forget you have a regular job and are not here just for my entertainment.
Lol, thanks man. I'm glad you're entertained. Job, wife, 4 kids 6 Jeeps 🤣🤣
Now all that grease is going to collect brake dust and dirt.
Other than that, decent video
Thanks man! ill wipe em down before i install em.. for now Ill take dirt over rust any day! lol