D 44 disc brake conversion

[xjtimxj]

I just recently got a d44 rear axle out of an old cherokee. I am upgrading gears and lockers, but first want to tackle the disc brake conversion. Does anyone have any tips or pointers on what parts I will all need. I have found the kit on various offroad sites but hundreds of dollars for this conversion does not seem right. I know many people on here could help.
Thanks, XJTIMXJ

 

[96 XJ Sport]

Do a search on here for the ZJ rear disc conversion. You'll find all the info you need. The hardest parts to find are the ZJ backing plates, but any good junkyard should have them. I bought some from a member on here, then bought new calipers and rotors, but of course you could go junkyard on those too. Oh, and get the rubber brake lines from the ZJ when you go to the junkyard.

I did this on an 8.25 recently, but from what I remember the process for the D44 was almost identical. A little patience with a dremel and you're all set. Read up about the proportioning valve in the MC, too. Some say to swap it with the ZJ valve and some say it's not necessary. I found it not necessary in my case.

 

[egotripp]

Do a search on the write ups. You can use Ford CV parts from the JY much cheaper then buying a kit. I did one on my 8.25 for less then $200 that way.

 

[xjtimxj]

awesome, thanks for the input. ill check those out. unless anyone else has anything else to say, haha.

 

[XJ&CHZ4ME]

Eric nailed it. I have done multiple ZJ disc swaps adn have never spent over $150. I go to a pick-n-pull or U-Wrench-it and pull my own parts. You will need to open teh hole in the center of the backing plate to get it to clear, but all in all it is fairly easy and can be done in a good afternoon. I have done it on a few 8.25's and a buddys D35 (insert joke here). The D44 may be a little different, but should be easy enough. It has been covered many times in the mod tech forum.

 

[BIGSLVRXJ]

I'm pretty sure the D44 conversion requires a lot more precision and work than converting a Dana 35 or Chrysler 8.25 with ZJ plates. I'm also almost positive it's a lot harder to use the ZJ backing plates in this case than it would be if you were using Explorer 8.8 rear disk brackets. Do a search for Explorer brakes on a Dana 44, that should yield some good results. Hope it helps.
-Collin

 

[jakeWI]

Ill have to make a list of the parts that are on my 44.

Its a mix of ZJ and Rubicon 44 parts.

 

[comancheon33]

I have discs on my 44 in my MJ. I used 8.8 brackets and calipers with ZJ rotors. The pattern on the 8.8 brackets is alot closer than the ZJ stuff. It also requires a spacer for the bearings and seals to make it work. Some guys use rubicon retainers but they require quite of modificatio to fit. I bought the spacer from another company that makes conversion kits. Name escapes me @ the moment. The swap requires alot more work on a 44 versus an 8.25 or 35. The latter is basically a bolt on with a little extra work needed to make it fit. If you use the 8.8 parts you basically elongate the mounting holes and that will get the brackets on then slide the axles in with the spacer between the seal and reatainer. The spacer puts the seal and bearing back into the housing where needed with the thicker disc brake brackets. After that slide on a pair ZJ rotors because the center hole is right size, 8.8 you have to enlarge the center hole in the rotor. 8.8 calipers and pads with two right side caliper to line rubber hoses. Bleed the brakes and check for leaks.

 

[chpmnsws6]

Wow, this actually makes me happy I had an 8.25 rear!

 

[jakeWI]

Ok.

Calipers, Pads, Rotors and Caliper Brackets were ZJ d35

Bearing Retainer/Spacer is TJ Rubicon 44