This pages covers the rear disc brake conversion, U-bolt flip and 4 link type bar system that I installed on my Dana 60 rear axle.
The disc brake conversion I did on my Dana 60 rear axle was done with the following parts:
- The Discs are off of the front mid 70's-80's 3/4 ton Chevy trucks. The Napa part number is 4885677 and They were $47.49 each.
- Calipers are from the rear of 76-78 Cadillac Eldorado, they have a built in emergency brake. The Car Quest part number is CAL 18-4117 & CAL 18-4116 (one left one right) and they were $86.12 each including a core charge.
- Bolts to hold the calipers on are NAPA part number 82205 and are $13.12 a pair.
- Brake pads were $32.00 for both sides, I don't have the part number.
- Brake hoses are NAPA part number 4136797, I don't know what they are off of, but they work. They are $14.49 each.
All totaled up it adds up to $354.44. I found a big price range on the calipers, all the way up to $150.00 each, so it pays to call around. You might beable to find parts at a junk yard but I would just as soon have new parts the first time.
I also upgraded the lug bolts from 1/2" to 9/16" as long as I had them all out. NAPA part number 6413162 will press right in to place for $2.98 a piece. I don't know what they are suppose to fit but they work.
ROTOR ASSEMBLED ON TO THE HUB WITH THE NEW 9/16" LUG NUTS
THE CALIPER BRACKET IS MADE OF 3/8" PLATE STEEL, THE SMALL CENTER SECTION IS WELDED IN AFTER BOLTING TO THE AXLE FLANGE. PROBABLY NOT A NECESSARY PIECE BUT MORE IS BETTER. CLICK HERE IF YOU WOULD LIKE TO PRINT A PATTERN IMAGE OF THE BRAKE BRACKET, I DON'T KNOW IF ALL DANA 60'S HAVE THE SAME BOLT PATTERN AND FLANGE SIZE.
I BOLTED THE BRACKET TO THE AXLE FLANGE WITH GRADE 5 BOLTS AND WELDED THE CENTER PIECE IN
ON THE BACK SIDE ONLY, I DIDN'T WELD THE FRONT SO IT WOULD BE EASIER TO GRIND OFF THE WELD
IF THE BRACKET NEEDED TO BE REMOVED FROM THE AXLE. NOTE ON THE LEFT PICTURE YOU CAN SEE
WHERE I HAD TO GRIND INTO THE FACE OF THE PLATE TO MAKE A LITTLE MORE ROOM FOR THE BRAKE
PAD. I ALSO HAD TO GRIND OFF THE RIVET THAT HELD THE PAD WEAR INDICATOR ON AS IT WAS IN
THE WAY. IF YOU WANTED IT TOO LOOK CLEANER YOU COULD MILL OUT THE FACE OF THE BRACKET, BUT
ONCE IT IS TOGETHER YOU CANT SEE IT. YOU COULD ALSO MAKE A SPACER TO GO BETWEEN THE
BRACKET AND AXLE FLANGE.
THIS IS THE COMPLETED ASSEMBLY. NOTE THE BRACKET TO THE RIGHT OF THE SPRING PAD. THIS WILL MOUNT THE SHOCK AND THE BOTTOM BAR OF MY FOR LINK. BECAUSE OF THE U-BOLT FLIP YOU NEED SOMEWHERE TO MOUNT THE SHOCK BECAUSE THE LOWER BRACKET THAT THE U-BOLTS WENT THROUGH AND SHOCK MOUNTED TO IS NO LONGER USED. AND THE LITTLE BRACKET JUST BELOW THE SPRING PAD WAS MADE TO HOLD THE BRAKE LINE.
THESE ARE THE PLATES I MADE FOR THE TOP OF THE SPRING PACKS THAT THE U-BOLTS WILL GO THROUGH. IT ALSO HAS THE MOUNT ON IT FOR THE TOP BARS OF MY FOUR LINK SYSTEM.
I left the stock master cylinder and portioning valve in and the system works beautiful. The brake feel is much more solid and you can feel the back brakes doing something. I do run the 38" tires, so if you are running smaller tire their may be too much rear break, but with the 38's it is about perfect, now I just need away to get more power out of the front brakes. No more readjusting the back brakes after a day in the mud. I haven't completed the emergency brake hook up's either, I will post the pictures for that as I get it done.
I do not have pictures of the finished U-bolt flip or the 4-link install yet but it wont
be long before I post them. I can tell you that the four link works great and really hold
that rear end where it belongs and helps with traction off the line.
