04lvl2
May 01 2006, 09:21pm
Explorer Rear Disc Brake Conversion
This installation was done on the 31 spline axle of a Level II and that this kit will only fit that axle. In other words, the major components will only bolt on to the axle in a 2002 FX4 or a 2003-on Level II. As you know, adapting it to the much more common 28-spline axle would require significant modification of the caliper mounting castings and/or the axle flanges.
First of all we will lay out the parts list.
Ford Racing Parts Rear Disc Brake kit – M-2300-G
Parking brake cables from local parts store or junkyard from 96-01 Explorer
Two passenger side brake hoses from local parts store or junkyard from 96-01 Explorer
Banjo bolts for rear calipers – Ford Part Number -385116-s2
Spider block bolt (If reusing the old one apply thread locker) D8BZ-4241-B
75w-140 Gear Lube (I used Mobil 1 SynPower Full Synthetic as this was what they had at the parts store)
http://www.fordracingparts.com/parts/part_details.asp?PartKeyField=1790
This is the kit from ford racing the link to it is above.
http://zeebone.com/gallery/d/33821-1/M2300G+kit+picture.jpg
Direct Quote from the website:
This rear disc brake kit may be low buck, but it really works! Kit includes 11" rotors, calipers, mounting brackets and attaching hardware. The rotors have the popular 5-hole, 4.5" diameter passenger car bolt pattern. Caliper mounting brackets fit the popular 8.8" Truck/9" Late Ford axle housings with 2" x 3.56" pattern and big 3.15" diameter bearing. This kit is designed for vehicle installations with a 2.5" brake gap (housing flange-to-axle shaft flange).
The reason I highlight this is due to my ignorance when I measured the brake gap. This caused me some really unneeded stress and aggravation. You have to measure from the axle housing flange to the outside of the axle. It should be 2.5 inches. The other part is this will only bolt up to a 31 spline big bearing axle.
http://zeebone.com/gallery/d/33823-1/Offset.jpg
I used the parking brake cables and rear brake hoses from a 99 Ford Explorer 4wd and am currently investigating other options for the passenger parking brake cable as it is not long enough.
This kit has also been made to work on the 28 spline 8.8 axles by welding up the mounting plate and backing plate holes, redrilling the holes and then mounting. Not sure if I would go this direction but will include the link for your viewing.
http://www.therangerstation.com/Magazine/Fall2003/Converting_your_Ranger_8.8_to_Explorer_disc_brakes .htm
Now to the good parts.
1. Chock the front tires in the front and rear to reduce the chance of the vehicle rolling.
2. Jack the rear axle up and support with jack stands.
http://zeebone.com/gallery/d/33863-1/DSCF3120.JPG
3. Remove the tires and place off to the side for later reinstallation.
4. Remove the brake drums (They make take some kind taps from a hammer to be removed)
http://zeebone.com/gallery/d/33868-2/DSCF3121.JPG
http://zeebone.com/gallery/d/33875-1/DSCF3124.JPG
5. Remove the brake shoes and hardware from the backing plates.
http://zeebone.com/gallery/d/33869-1/DSCF3122.JPG
Pull some slack down in the emergency brake cable and clamp the line up front at the frame. If you have done a body lift then you should know how to do this already. With the line clamped you should have slack in the line like this.
http://zeebone.com/gallery/d/33752-1/DSCF3154.JPG
Separate the intermediate cable from the rear cable so the rear lines can be removed from the truck. This is where the two lines meet and connect the cable that goes to the front of the truck. There are a few retainers on top of the axle that have to be released to remove the cable. I have found that a pair of needle noise pliers works best to release the retainers from the lines.
Place a drain pan under the rear axle and remove the lower bolts working your way up to the top bolts. Reason for this it will allow the bottom of the cover to come out slowly and reduce the chance of a mess.
http://zeebone.com/gallery/d/33886-1/DSCF3127.JPG
Remove the bolt/pin from the rear axle that holds the spider block. Be careful with this bolt as it pretty tight and can snap easily. I purchased a new one for a few dollars at the Ford Dealer.
http://zeebone.com/gallery/d/33929-1/Spider+bolt.jpg
This installation was done on the 31 spline axle of a Level II and that this kit will only fit that axle. In other words, the major components will only bolt on to the axle in a 2002 FX4 or a 2003-on Level II. As you know, adapting it to the much more common 28-spline axle would require significant modification of the caliper mounting castings and/or the axle flanges.
First of all we will lay out the parts list.
Ford Racing Parts Rear Disc Brake kit – M-2300-G
Parking brake cables from local parts store or junkyard from 96-01 Explorer
Two passenger side brake hoses from local parts store or junkyard from 96-01 Explorer
Banjo bolts for rear calipers – Ford Part Number -385116-s2
Spider block bolt (If reusing the old one apply thread locker) D8BZ-4241-B
75w-140 Gear Lube (I used Mobil 1 SynPower Full Synthetic as this was what they had at the parts store)
http://www.fordracingparts.com/parts/part_details.asp?PartKeyField=1790
This is the kit from ford racing the link to it is above.
http://zeebone.com/gallery/d/33821-1/M2300G+kit+picture.jpg
Direct Quote from the website:
This rear disc brake kit may be low buck, but it really works! Kit includes 11" rotors, calipers, mounting brackets and attaching hardware. The rotors have the popular 5-hole, 4.5" diameter passenger car bolt pattern. Caliper mounting brackets fit the popular 8.8" Truck/9" Late Ford axle housings with 2" x 3.56" pattern and big 3.15" diameter bearing. This kit is designed for vehicle installations with a 2.5" brake gap (housing flange-to-axle shaft flange).
The reason I highlight this is due to my ignorance when I measured the brake gap. This caused me some really unneeded stress and aggravation. You have to measure from the axle housing flange to the outside of the axle. It should be 2.5 inches. The other part is this will only bolt up to a 31 spline big bearing axle.
http://zeebone.com/gallery/d/33823-1/Offset.jpg
I used the parking brake cables and rear brake hoses from a 99 Ford Explorer 4wd and am currently investigating other options for the passenger parking brake cable as it is not long enough.
This kit has also been made to work on the 28 spline 8.8 axles by welding up the mounting plate and backing plate holes, redrilling the holes and then mounting. Not sure if I would go this direction but will include the link for your viewing.
http://www.therangerstation.com/Magazine/Fall2003/Converting_your_Ranger_8.8_to_Explorer_disc_brakes .htm
Now to the good parts.
1. Chock the front tires in the front and rear to reduce the chance of the vehicle rolling.
2. Jack the rear axle up and support with jack stands.
http://zeebone.com/gallery/d/33863-1/DSCF3120.JPG
3. Remove the tires and place off to the side for later reinstallation.
4. Remove the brake drums (They make take some kind taps from a hammer to be removed)
http://zeebone.com/gallery/d/33868-2/DSCF3121.JPG
http://zeebone.com/gallery/d/33875-1/DSCF3124.JPG
5. Remove the brake shoes and hardware from the backing plates.
http://zeebone.com/gallery/d/33869-1/DSCF3122.JPG
Pull some slack down in the emergency brake cable and clamp the line up front at the frame. If you have done a body lift then you should know how to do this already. With the line clamped you should have slack in the line like this.
http://zeebone.com/gallery/d/33752-1/DSCF3154.JPG
Separate the intermediate cable from the rear cable so the rear lines can be removed from the truck. This is where the two lines meet and connect the cable that goes to the front of the truck. There are a few retainers on top of the axle that have to be released to remove the cable. I have found that a pair of needle noise pliers works best to release the retainers from the lines.
Place a drain pan under the rear axle and remove the lower bolts working your way up to the top bolts. Reason for this it will allow the bottom of the cover to come out slowly and reduce the chance of a mess.
http://zeebone.com/gallery/d/33886-1/DSCF3127.JPG
Remove the bolt/pin from the rear axle that holds the spider block. Be careful with this bolt as it pretty tight and can snap easily. I purchased a new one for a few dollars at the Ford Dealer.
http://zeebone.com/gallery/d/33929-1/Spider+bolt.jpg