Rear Disk brake Conversion

[Rockdawg84]

So I had to do rear axle seals (been leaking for a while now) So I thought what the heck I'll do a rear disk conversion. I was actually inspired by some 1st gen runner guys on Pirate.

First pull the axle shafts and do axle seals. Done :tongue:

Next use a cutoff wheel or plasma cutter, or torch to cut around the mounting flange taking care not to put too much heat into the bearings and keep a fire extinguisher handy. rear axle oil is flammable.
Rear Disk 1 by Sam Wright, on Flickr

I used the following parts. brake rotor from the rear of a 94 Montero Sport. Rear Caliper from 94-04 Mustang Gt. Custom flex line with banjo connector.
Rear Disk Brake 3 by Sam Wright, on Flickr

Rear Disk Brake 7 by Sam Wright, on Flickr

Rear Disk Brake 8 by Sam Wright, on Flickr

Rear Disk Brake 5 by Sam Wright, on Flickr

Next you have to remove 2 of the axle bolts. We used a air hammer, but it is possible to install the axle shafts and only bolt in the bottom 2 and then drive out the top 2. These will be replaced later.

Then you have to build a bracket to hold the caliper.

Here is my prototype
Rear Disk Brake 20 by Sam Wright, on Flickr

Here is the torched bracket made of 1/4" plate
Rear Disk Brake 4 by Sam Wright, on Flickr

cleaned up and drilled and painted

Rear Disk Brake 11 by Sam Wright, on Flickr

Now you have to shim the caliper bracket so the Caliper is centered on the rotor.
Rear Disk Brake 14 by Sam Wright, on Flickr

Rear Disk Brake 13 by Sam Wright, on Flickr

Rear Disk Brake 10 by Sam Wright, on Flickr


I cut and reflared the hard line to create a better angle for the flex line.
Rear Disk Brake 9 by Sam Wright, on Flickr

Bolt it all together, bleed the brakes and there you go.

Rear Disk Brake 10 by Sam Wright, on Flickr

Reinstall the tire and enjoy extra stopping power, Brakes that don't cake up in mud and snow, and you can work on the rear end with out cracking open the brake system.
Rear Disk Brake 15 by Sam Wright, on Flickr
Rear Disk Brake 18 by Sam Wright, on Flickr

 

[Rockdawg84]

So the second part is to get the parking brake done. I used mustang gt factory cables including the equalizer cable, and a custom bracket for everything to fit into. Then modified the factory cable.

So here are some pics

started from the rear of the truck at the mustang caliper and ran the line up toward the front. As a note mustangs have a right and left that are different lengths. Buy 2 of the shorter ones.
Parking brake install by Sam Wright, on Flickr
Parking brake install by Sam Wright, on Flickr

Then a bracket was made for the cables to fit into. a simple piece of 1.5" angle iron was used. Holes drilled for the cables to fit into and 5 holes drilled so the bracket could be riveted into the floor support. Nice that toyota put that there for us to use and not have to drill all the way through the floorboard.
Parking brake install by Sam Wright, on Flickr
Parking brake install by Sam Wright, on Flickr

Then we cut the equalizer cable up so we could get the bracket and the boot.
Then the stock parking brake cable outer casing was cut and we left the inner cable long. the boot was put on and attached with zip ties.
Parking brake install by Sam Wright, on Flickr
Parking brake install by Sam Wright, on Flickr

Once the length was determined the equalizer was put on the cable and cable ferrules were used to secure it on the end.

Parking brake install by Sam Wright, on Flickr
Parking brake install by Sam Wright, on Flickr

Finally everything was put together and the cable was adjusted at the handle and it actually works! I'm very happy with how it came out. there are a couple of things to finish up, like securing the cables to the rear axle better and to source a new brake handle and cup underneath since I did the shift to the side mod with the 98 handle. Over time if I don't change it out the cable will fray and I will have to modify another stock cable. Over all I think it came out great, and looks pretty factory.

Parking brake install by Sam Wright, on Flickr
Parking brake install by Sam Wright, on Flickr
Parking brake install by Sam Wright, on Flickr

 

[4runner DOA]

Nice job.

 

[Dezert4Runner]

What was the reasoning for using the Montero rotor? Isn’t the common rotor used on these conversion s the 4th gen 4Runner ones?

 

[Blender]

is this from before you went FF?

 

[theesotericone]

What was the reasoning for using the Montero rotor? Isn’t the common rotor used on these conversion s the 4th gen 4Runner ones?

None of this was common before Midcoma on T4R made the bolt on kit. He sourced 4th gen rotors because they work with the hub and mustang calipers.

 

[Dezert4Runner]

None of this was common before Midcoma on T4R made the bolt on kit. He sourced 4th gen rotors because they work with the hub and mustang calipers.

I’m familiar with his kits but I could have sworn I’ve seen a couple others using the same setup before he made his kits available. Maybe it’s off TTORA but I know he was also on that forum and could have just been info I read that he was involved with long before he posted available kits on T4R.org.

 

[Rockdawg84]

Nice job.

Thanks.

What was the reasoning for using the Montero rotor? Isn’t the common rotor used on these conversion s the 4th gen 4Runner ones?

I used the Montero rotor because it was a good starting place and it's the one the 1st gen guys on pirate used. I went to Auto Zone and had them pull the rotor and then I had them pull a bunch of rear brake calipers that had mechanical parking brake actuators. I decided on the Mustang calipers because I felt that they would balance well with front 13WL tundra calipers. The Montero rotors also are deeper than the 4th gen rotors and it made it easier to build the mount for the caliper.

is this from before you went FF?

yes but the FF didn't change anything except the caliper mount. It was about 9 years ago that I did post one but the parking brakes finally happened this week. LOL.

None of this was common before Midcoma on T4R made the bolt on kit. He sourced 4th gen rotors because they work with the hub and mustang calipers.

I’m familiar with his kits but I could have sworn I’ve seen a couple others using the same setup before he made his kits available. Maybe it’s off TTORA but I know he was also on that forum and could have just been info I read that he was involved with long before he posted available kits on T4R.org.

I did this originally in January of 2012 but this last year Midcoma made the kit and it is nice. The original idea came from 1st and 2nd gen pickups on Pirate4x4 and they were using front calipers, I simply applied the idea to a 3rd gen and found a rear caliper that would accommodate a parking brake. It just took 9 years to get the parking brake done.

 

[cbechtold]

This is pretty slick. I've been thinking about swapping the rear of my Tacoma to disc brakes. What size rim are you running? If you think this'll work with 16s, I'm going to be very tempted to send it.

 

[Rockdawg84]

This is pretty slick. I've been thinking about swapping the rear of my Tacoma to disc brakes. What size rim are you running? If you think this'll work with 16s, I'm going to be very tempted to send it.

I'm running 17's but I'm pretty sure that 16's would fit. I can do some measurements tomorrow for you.

 

[Dukestaco]

Nice job.

 

[Rockdawg84]

Nice job.

thanks. its been a great conversion but I'm really happy to finally have a parking brake again. It's a big deal when you have a 5speed. LOL

 

[Dukestaco]

thanks. its been a great conversion but I'm really happy to finally have a parking brake again. It's a big deal when you have a 5speed. LOL

I had the same issue on my Zuk. I put a line lock in but only good as long as you have voltage. Don’t have the zuk anymore just waiting to tear into the 4runner.

 

[MattJakobs]

This is pretty slick. I've been thinking about swapping the rear of my Tacoma to disc brakes. What size rim are you running? If you think this'll work with 16s, I'm going to be very tempted to send it.

I've got a 3rd gen T4R buddy running this with 16x8 SCS F5 3.5" BS and it's given him no problems.
He is running the Montero rotors, not 4th gen 4Runner rotors.

 

[cbechtold]

I've got a 3rd gen T4R buddy running this with 16x8 SCS F5 3.5" BS and it's given him no problems.
He is running the Montero rotors, not 4th gen 4Runner rotors.

Good to know! Would be rad to see this and Tundra brakes on my truck make a huge difference in braking performance!

 

[MattJakobs]

Good to know! Would be rad to see this and Tundra brakes on my truck make a huge difference in braking performance!

I still haven't forgotten about grabbing those calipers for you!

Tundra brakes made a huge difference for me, you'll definitely be happy with them.
I have everything needed to do rear disc brakes besides time. Hopefully soon, and after the front is done...

 

[cbechtold]

I still haven't forgotten about grabbing those calipers for you!

Tundra brakes made a huge difference for me, you'll definitely be happy with them.
I have everything needed to do rear disc brakes besides time. Hopefully soon, and after the front is done...

Sweet! Let me know when you have them. Very much looking forward to having good brakes again!

 

[clntg]

Great work. I’ll keep this in mind as I rebuild the rear if the truck later this year.

But until then... I just swapped the 4Runner wheel cylinders in my rear drums for ‘06 Tundra wheel cylinders last weekend. Along with the front Tundra conversion I did years ago (now ‘06 Tundra front and rear)... the truck really stops.