my new axles!

[OlllllllO]

Well here it is! All finished and ready to ROCK! My TJ now sports XJ HP Dana 30, 4.56 gears, diff guard, Lock-Rite locker, chromoly shafts, superior tube seals and XJ D44, 4.56 gears, diff guard, Aussie locker, chromoly shafts, ZJ disc break conversion. Took a small chunk out of the wallet and a couple nights on the couch with out the wife to finally get it done and swapped. I purchased these from a dude on here as a set for $900. All I did to mess with the rear was get new brackets on ,ZJ disc brake conversion and a couple little nit noid things. The front was a direct bolt in. But its done and I feel good about it. Now we wait till labor day weekend at uwharrie to really try em out.
Heres some pictures from start to finish of the build:

Heres the front end which was 90% finished already. Just had to replace the upper CA bushings and wheel bearing units.

Heres the rear with the stock XJ brackets and drums before the transformation.

Chromo shafts that came with the purchase but needed bearings, retainers and spacers.

Heres both axles together with the rear brackets finished. Still needed the shafts parts at this point.

And the finished product under the rig!

 

[OlllllllO]

heres the ZJ discs on a XJ axle on a TJ.

didn’t have the ZJ original e brake cables so until I get it welded, there they lay with out use. I ill be using a parking block until cables are done.

Front…

finished product!

 

[rob92xj]

Looks good Jon, now are you ready to get some mud on them tires?

 

[OlllllllO]

haha! yeah, maybe you could show me around. you headed up to uwharrie on labor day?

 

[ihaterice]

Very nice! I'm about to have the exact same setup minus the chromo's and rear disc's.
Just finished regearing my rear d44 and threw in an aussie and found a hp 30 front with a lockrite. Just need to regear it and put it in, and i have SOLID covers for both. For the zj disc brakes, they can come of a zj d35 right? basically any zj rear diff with discs and everything just can be swapped over? How hard was it doing a parking brake too?

 

[Airdoc]

Nice Upgrades.

Quick Question - did you add any brake proportioning with the addition of discs in the rear?

I ask b/c i'm about to put an 8.8 with rear discs and curious if changes will be needed.

 

[OlllllllO]

the issues with this disc brake conversion was that the bolt pattern for the back plates on the ZJ where different with XJ pattern. so to correct that, you needed to measure for new pattern and drill holes to fit for the receiving end. then the axle tubes are bigger so the ZJ back plate hole needed to be bigger. THEN since it was a ZJ back plates to XJ axle, you need custom spacers to close the play between the shaft retainer and seal.

here are some sites that helped a ton with my conversion. they explain everything you will need:

for ZJ disc brake conversion on TJ axle.
http://www.stu-offroad.com/suspension/d44brake/bc-1.htm

for ZJ disc brake conversion on XJ axle. (this was my big one)
http://www.madxj.com/MADXJ/technical/technicalfiles/BAzjRearDiscsOnXJ/ZJrearDiscsOnXJ.htm

hope this helps!

 

[My_samurai]

rear pinion looks a lil high

 

[OlllllllO]

rear pinion looks a lil high

no vibes here...

 

[rob92xj]

Nice Upgrades.
Quick Question - did you add any brake proportioning with the addition of discs in the rear?
I ask b/c i'm about to put an 8.8 with rear discs and curious if changes will be needed.

On the proportioning valve there is a rubber cover covering a screw remove the screw on the end of it is a o-ring remove the o-ring reinstall screw full fluid flow to the rear brakes, just like a factory disk/disk prop valve.
http://www.4x4wire.com/jeep/tech/brakes/xj_wjbrakes03/valve/index.htm

I hope this helps I'm running the ZJ disks on my 8.25 in my XJ and it stops a whole lot better my next brake mod is going to be the later model brake booster.