The Big Green Build Thread (Updated 1/27/09)

[rckrdyxj]

Good News and Bad News.

THE GOOD:The gears and install kit came in today but the detroit locker will be in tomorrow hopefully.

THE BAD. The ZJ/TJ disc brake swap does not work for XJ D 44 axels. Its supposed to be a bolt on for the tj D 44 with drums and i was told It would work for the xj D44 as well.

The part numbers for the loaded backing plate and retainer plate given by the link do not fit xj d44. Directly w/o drilling. Thread says its a bolt on setup but for a tj d44 with drums. i guess the d 44 is the same setup for every jeep d 44 but teh xj d 44.

Here is the link for what i was going to use.

www.stu-offroad.com/suspension/d44brake/bc-1.htm


SO back to the drawing board to decide what disc brake swap i will use.

[crosbike]

whats the difference between tj and xj?

[rckrdyxj]

What is different is the bolt pattern for the caliper mounting bracket and the dust shield nad the retainer plate. To use what i have i will have to get everything i just bought, redrilled to work like in the ZJ disc brake swap thread in sams post on page 2.

I have ruled out that this will be a bolt on setup. I may just go and re drill everything but i am researching more first. Before i redrill $180 worth of loaded backing plates. (includes the backing plate, caliper bracket and e brake parts pre assembled)

I cannot decide whats the better route. Redrill the retainer plate and get for crown vic brakes that do bolt on. and return wha ti already bought.

or

Keep what i have, Have a machine shop redrill the backing plates, retainer plates and caliper brackets.

IMHO i think i should go the crown vic route.


Basically any of the three listed disc brake swaps will work but modification is needed to make them work on an XJ d 44.

Uses Crown vic brakes with a modified tj retainer plate for spacing .
jeepin.com/features/cvdiscs/index.asp

Uses ZJ brakes that will be redrilled along with a new or redrilled retainer plate.
www.madxj.com/MADXJ/technical/technicalfiles/BAzjRearDiscsOnXJ/ZJrearDiscsOnXJ.htm

Uses TJ or ZJ discs with redrilling for xjs w/o redrilling for tj d44. basically the same as the 2nd link.
www.stu-offroad.com/suspension/d44brake/bc-1.htm


Combine all 3 and you will have working 100% jeep disc brakes on an xj d 44.

[HeavyMetal]

i have never seen such an issue with it, i dont understand what the deal is

JF is chock full of people who have done the zj swap without trouble, as well as naxja

are you absolutely certain you have all the correct shit

[rckrdyxj]

Yes i am positive I read the part numbers directly from the printed page of the thread. The only way these parts will fit will be to drill them just like in the zj disc brake swap thread.

There is a difference (very noticable by looking at it) in the bolt pattern of the xj d 44 and the tj/zj d 44.

The only setup that bolts on is the crown vic setup.

[rckrdyxj]

Locker, gears and Install kit here, Getting crown vic brakes next weeek and hopefully the gears set the week after.

[rckrdyxj]

SCORE I was going out to do some errands on this rainy sat and i saw that the local u pull was open. I pulled in because the rain seemed to have subsided for a few minutes. I grabbed my tool box and went to get some ZJ proportioning valves. I snagged two for $10. While i was on my way out i saw a crown vic taxi sitting there. Sure enough it had rear discs. TO my surprize the axel shafts were already out so i began to pull the caliper brackets. Got both brackets and both ZJ Prop valves for $40.

[KtmRacer419]

dont tell will. he will hate you

[rckrdyxj]

I bet he will.

[rckrdyxj]

From the left.

Detroit locker, Timken master overhaul kit, 4:56 gears.


Not that most of you dont know what these things look like but i am excited so her eare mroe pics.

Detroit locker.


Master Overhaul kit.


4:56 gears.


Brand new Craftsman grinder.



Its like they were meant to be there from teh factory.

Crown vics in place for mock up. Will get new un bent dust shields and wire brushing with some black paint.





The Detroit begging to be installed.


ZJ proportioning valves. 1 for me and 1 for will.


TJ retainer plates are being welded this weekend and i will redrill the bolt holes next week. Currie soft brake lines will be in next week as well.

Thats it so far. Lot done but a long way to go before its installed. and many more paychecks squeezed for every last penny for parts.

[Jeep Creep]

rckrdyxj said:

and many more paychecks squeezed for every last penny for parts.

i love doing that

[rckrdyxj]

I picked up rotors, all new hardware, and e brake shoes today. Loaded Calipers will be in tomorrow and i will also get all the hard lines i need.

I will order the new backin/dust plates later this week, $62 bucks each for a sheet of metal. WTF?

Oh well, it will be sick when its done.

In two weeks when i am ready to get the gears set i will order and paint the Riddler Diff cover.

[crosbike]

Are you putting in your gears yourself? how much were your gears if you dont mind me asking

[rckrdyxj]

I am having a local shop do the gears. Its a shop i have done a bunch of business with before and sent alot of people too so he is cutting me a deal. $300 to do th rear. I will go back in a couple weeks for the front. Other shops wanted up to $750 per axle.

I am not 100% on the cost because i dont remember where i put the slip but i think it was like $150 for the gears (in that area) and like $80 for the install kit but i am not sure. I got it all from DC 4WD.

In a week or two i am ordering the front gears, master OH kit, Superior axle seals, and Riddler front diff guard and 4* RE leaf spring shims and u bolts.

All teh major drive line parts are from dc, but the riddler diff guards are from jeepinoutfitters, and the brakes are all local stuff.

[crosbike]

wow a little pricey on the gears. not too bad for install price tho