Originally Posted by tcoche
OK! I FOUND A 1996 ZJ THAT IS A DANA 44..NOT A DANA 35..SHE SAID IT HAS DISC BRAKES. I WONDER IF THAT WILL WORK?? SHE SAID SHE WILL SELL ME THE DISC BRAKE CONVERSION FOR 200 BUCKS. CAN ANYONE BE ABSOULTELY POSITIVE THAT A 1996 ZJ DANA 44 DISC BRAKES WILL WORK ON A 2004 LJ DANA 44??
Alright, a few things. I don't believe that is a 2004 axle from an Unlimited and even if it's not, it's not a big deal. The clues that point me to that conclusion are the fact that it doesn't already have rear discs and the bearing cap isn't slotted for the Rubi locker air line.
I realize someone could have swapped on the brake drum backing plates, but you also have axles that have the appropriate 4 bolt retainers for drum brakes. That means they either tossed in some shafts and backing plates from another 44, or it's not from an Unlimited.
I don't believe that they made any rear 44's after 03 without the slotted bearing cap.
That said, no the brakes from a 96 ZJ will not directly swap. However, if you read Stu's write-up from when we did his, you will discover that they can easily be adapted to work.
What I haven't seen anyone tell you yet is you will need to pull the bearings, seals, and shaft collars from the axles you have in order to use the 4 bolt retainers for disc brakes. That means you really should replace all the bearings and seals while you are at it. Those are a Set 10 and make sure you get the 3 pieces. Some places sell the Sets without the shaft collars.
Brakes that will swap or can be made to swap are as follows-
All TJ's and regardless of the body code, Rubi's and Unlimiteds are still TJ's.
8.8 rear discs will NOT work unless you want to have a lot of machine work done and weld up the holes in the backing plate.
To swap the discs on you will need the following parts-
Disc brake 4 bolt retainers
Shaft collars if you decide not to change out the bearings and seals.
Bearings and seals Set 10
Short flex hoses
Parking brake cables for disc
Flex hose tabs for the ends to bolt or weld to the housing
Cut and flaring tools to shorten and adapt your brakes lines to the flex hoses
New longer bolts for the backing plates with Grade C top lock nuts. Drum brake bolts are too short.
Backing plates with dust shields
Calipers with new crush washers and banjo bolts
You can re-use your brake line that attaches to the axle via the vent bolt.
about do it.