ZJ Rear Disc Conversion to 8.25" Write Up - The Whole Truth!!! - Page 2 - JeepForum.com
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post #16 of 48 Old 11-23-2008, 09:00 PM
XJohnnyC
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Originally Posted by dcorn View Post
It would be tough to pull the axles to get the backing plate in a junkyard though
Pull the cover off, take the c-clips out, pull out the shafts. Pretty easy stuff.

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post #17 of 48 Old 11-23-2008, 09:28 PM
johnsoninc86
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thats a good write up. I need to still put the e-brake assembly on mine, and I might have to use the Liberty cables. I ended up pulling the o-ring out of my prop. valve, and all my wheels pretty much lock up at the same time, and I've been real happy with it. Its saved my but from hitting deer head-on several times.

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post #18 of 48 Old 11-24-2008, 09:14 AM
89SAFARIXJ
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holy crap man. amazing write up. i will use this cuz i tihnk im gonna do mine.

-Sean


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post #19 of 48 Old 03-05-2009, 11:16 PM
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Do you lose the abs with this conversion? Or is there a way to rig the sensors?
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post #20 of 48 Old 03-06-2009, 06:00 AM
lurkeryj
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Originally Posted by DNNDRTY View Post
Do you lose the abs with this conversion? Or is there a way to rig the sensors?
why would you lose abs? on a solid axle, abs sensor is in the pumkin generally
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post #21 of 48 Old 03-06-2009, 09:06 PM Thread Starter
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Originally Posted by DNNDRTY View Post
Do you lose the abs with this conversion? Or is there a way to rig the sensors?
I assume you could get the ABS to work. The ZJ I got the setup from had ABS, and the sensors attach to the brackets. However, this writeup is for using the ZJ brakes on a Chrysler 8.25 rear, which wasn't available with ABS in a Cherokee. If you have ABS, you have a Dana 35, and that's a different axle setup from the 8.25. Hope that helps!

Steve Ragusa - North Jersey
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post #22 of 48 Old 03-06-2009, 09:19 PM
kzjim
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Great write up.. !.. this should get stickied or added to FAQ..

Good to know about the liberty hardware being a direct swap. I just redid my rear drums and im less that thrilled.. its better but not great and the ebrake still dosent hold on my driveway... how does you ebrake hold now?

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post #23 of 48 Old 03-10-2009, 12:13 PM Thread Starter
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Jim, the parking brake holds just fine; my parents house has a pretty steep driveway, and I can put the ebrake on in their driveway with the Jeep in Neutral and it doesn't move. Passed at NJ State safety inspection back in January also, no issues. It just took a few trips up and down the driveway to get it adjusted just right.

Sorry I didn't respond sooner, we're in the middle of doing an addition on our house and I haven't had time to check the site in a few days.

Steve Ragusa - North Jersey
'01 XJ - SOLD!

'06 Infiniti G35x - coupe front springs, tint, FX35 18's, hitch for the bike rack.

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post #24 of 48 Old 03-10-2009, 01:50 PM
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TPI.. thanks for the reply.. I'm on the hunt for parts now... screw havin just redone the drums.. I'm tired of having to hear the wife complain about it not holding on the DW... the price of parts is worth not havin to listen to her..LOL

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post #25 of 48 Old 05-26-2009, 03:12 PM
Punishment
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Alright, alright great writeup, but where did you find the backing plates??? Junkyards will only sell me the entire rear end and the want as much as the conversion kit!!! I can buy the rest from O'riellys but I can't get the plates!
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post #26 of 48 Old 05-26-2009, 03:35 PM
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Nice writeup...

When I did this conversion I grabbed the parts from a salvage yard (calipers + brackets) and I was able to get the bracket mounting studs out of the ZJ D35w with a brass drift and BFH and then re-use them on my C8.25 (they are longer on the ZJ D35).

The wheel studs for a disc brake are longer than for a drum brake... When I did it I sourced "stock" studs from a local parts store and they ended up being about 1/16" shorter than the studs were with drum brakes.

Another option for e-brake cables is to use YJ Ford 8.8 conversion e-brake cables from MORE... They use the same style of e-brake and the are the right length. The KJ parts may be cheaper though.

One thing you didn't mention is that you need to connect the XJ hard lines to the caliper with mini soft lines. I used the ones I pulled off the junkyard ZJ... Did you buy new ones? I looked for SS braided, but didn't find any.

JW

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post #27 of 48 Old 05-26-2009, 04:29 PM
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Originally Posted by RckRdyXJ View Post
No ZJ came with an 8.25.


BUT Liberties came with an 8.25 29 spline with discs, and the discs are a 100% bolt on nonmodification direct swap on to any xj 8.25.
Not quite 100% bolt on. Read my article and especially the bit about the brake lines - KJ disc swap

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post #28 of 48 Old 05-26-2009, 07:50 PM
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Originally Posted by nostaw22 View Post
One thing you didn't mention is that you need to connect the XJ hard lines to the caliper with mini soft lines. I used the ones I pulled off the junkyard ZJ... Did you buy new ones? I looked for SS braided, but didn't find any.

JW
I used the factory ZJ lines when I did my conversion and they seem to do the job just fine.

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post #29 of 48 Old 05-27-2009, 11:04 PM
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so from what i am reading in here is that all zj's came with D35 and the disc setup will work on a 8.25 in an xj with modifications? just trying to be clear on what i need to look for. thanks.

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post #30 of 48 Old 05-28-2009, 02:18 AM
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Originally Posted by Punishment View Post
Alright, alright great writeup, but where did you find the backing plates??? Junkyards will only sell me the entire rear end and the want as much as the conversion kit!!! I can buy the rest from O'riellys but I can't get the plates!
if you go to a dealership, i think the backing plates arelike 15 bucks, since i paint cars for the jeep dealer, i was going to buy all new parts for my install,turned out everything except the backing plates cost a arm and a leg, so i just bought a used set of rear disc's.

ill be installing them this weekend.

94 xj - 5.5" rubucon express long arm, 4.56's, shafted & Detroit locked on 35's
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