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My
project to fit 98 ZJ D35 C-clip rear disc brakes to my '87 XJ D44. Note
that the XJ NON c-clip rear axle shares the bearing retainer bolt pattern
with the D44 so these instructions will work for the D35 non c-clip too.
All measurements shown.
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The
ZJ D35 axle I bought. It has c-clip axles and 3.55 gears
(open).
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ZJ
Right caliper assembly.
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Back
of right ZJ disc brake assembly.
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Caliper
and rotor removed, e-brake shoes visible.
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Axle
shafts removed from ZJ axle.
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Close-up
of ZJ assembly, showing flange bolt pattern.
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This
shows the difference. The center will need to be reamed out, the bolt
pattern welded and re-drilled to match, and a custom spacer (next pic)
machined to fit on the shaft outboard of the axle seal, to ensure the
bearing sits in the race properly. Note that the D35 NON c-clip axle
bearing retainer bolt pattern is identical to the D44, and so if you copy
what I did you can fit the ZJ discs on your d35 non c-clip the same
way.
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These
are the correct dimensions for the custom spacer to bear properly on the
seal.
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The
original setup on the axle shaft.
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The
arrangement of the little e-brake lever.
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Back
of the ZJ disc caliper bracket and splash shield.
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The
e-brake shoe assembly removed.
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The
splash shield and caliper mounting bracket separated.
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Once
you remove the splash shield, you have to remove the little rubber e-brake
lever boot.
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Back
of the separated caliper mount bracket. The larger hole to the left side
is the hole for the ABS sensor (not used by me).
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The
bracket, ready to go to the welders / machine shop. You need someone
experienced with cast steel to do the welding.
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The
XJ D44 bearing retainer plate overlaid on the caliper mounting bracket -
showing the difference in flange bolt pattern, and the need to weld up and
re-drill the caliper bracket.
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The
stock configuration of the bearing retainer plate against the axle
seal.
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The
stock configuration of the bearing retainer plate against the axle seal
2.
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The
bracket back from the shop, large hole enlarged to 3", and the D44 bolt
patter drilled. They would not weld the cast bracket.
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Bearing
retainer plate on the re-drilled bracket.
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The
machine shop wouldn't weld the cast bracket. Luckily it could be
re-drilled without welding.
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Custom
spacer sitting on the bearing retainer.
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Bearing
retainer in place, and custom spacer in background.
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Custom
spacer and seal in place on the retainer plate.
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Side
view of the seal on the spacer.
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All
the bits.
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The
spacer sitting on the seal.
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Exploded
view (kind of) :-)
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The
machine shop swore I'd have no problems as it was, but I just couldn't
leave it, so I plugged the hole with a steel putty, 18, 000 psi
compression strength.
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This
is the steel putty I used.
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The
NEW Dana 44 Disc Brake caliper bracket!
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The
NEW Dana 44 Disc Brake caliper bracket!
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Dust
shield re-installed.
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It's
starting to look good now.
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Here's
the arrangement of parts on the axle, including the custom spacer in
place.
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How
it will all sit when installed.
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I
turned the awful rusty rotors that came on the ZJ axle and they look
pretty good.
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In
goes the shaft with all the stuff on it.
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Bracket
and brake shoes in place, axle installed.
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Complete
except for rotor and caliper.
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Back
view assembled.
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Disc
in place It's looking REALLY good now!
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Calipers
on.
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One
last mod - I had to weld the XJ drum brake parking brake lever cable
fitting end onto the new lever (the ZJ has different cable ends). You
could just get ZJ cables, but I'm using the long YJ
cables.
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Sweeeeet
!!
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Complete
and installed!
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Left
side.
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Right
side.
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© Copyright 2001 Bill Ansel
All Rights
reserved.
Photos: Bill Ansell
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