Disc Brake Conversion Options / Suggestions 68 Cj5

Hi All - I looking for suggestions for Drum Disc Conversion on my 68 CJ5 V6 Dauntless 225.

The Jeep came w/ 1974 Dana 30 front & Dana 44 Rear ....
I'm looking to replace the Master Cylinder & - Not sure if I should upgrade w/power booster ? I have a frame mounted dual master cylinder already .... just wanted to get thoughts/guidance from people who possibly mounted a firewall booster & cylinder. I have no problem bending new lines & plumbing .

Also looking for thoughts on what Disc kits are out there and best way to tackle this ....

And if anyone has an Novak adapter for Sm420 to Dana20 that they want to sell let me know ...
That's the next project once I get these brakes figured out.

Greatly appreciate all the help and guidance.

 

For the front, not sure if it's relevant to a D30, but you might start by calling Sam at PartsDude4x4 near me out in Carson City. After I went through with installing the Kaiser Willy's front (D27A) disc conversion kit and milling my knuckles down, he told me he knew of other parts/options that would have been easier and cheaper.

 

There is a very long thread on disc brake conversions on the CJ2A forum that would be worth a read.

 

I did a complete swap of a front axle off a Roxor. The axle was a direct bolt on Dana 30/44 and came with disc brakes on it. I did need to add the Roxor steering linkage as well which was beefier tubing. It worked just fine and was really easy. The only issue I discovered was I needed to remove the Residual Pressure Valve (RPV) from the master cylinder, then add in a 10lb RPV to the rear brake line, and a 2lb RPV to the front brake line as the front discs were dragging.

I did a very detailed build thread on it. I still need to complete the tread regarding the brake drag issue, however I’m currently resolving that as I type this. It might be more than what you’re looking to do, but it solved a number of axle issues I was having.

 

My 73' Dana 30. I had to have the back side of the hubs machined to except the disc's.

 

I too have a 68' CJ5. Although I did not do the brake conversion, my jeep has dana 30 out of a 74 CJ5 with discs. You could of course gather wrecking yard parts from an appropriate donor....you'll have to do your research on this. Personally, I'd look into one of the kits in the spirit of both convenience and time....and because I live in a remote place with no wrecking yards. So Herm has a kit and Parts dude has a kit. There's probably others. Keep in mind that some wheels will not clear disc brakes. My aftermarket aluminum wheels barely clear.
Herms Disc Kit
Parts Dude

In terms of a power booster, I do not have one and do not feel like I need one, because my brakes work great without it (discs front, 11" drums rear, 33" tires). Boosters are big, take up space in the engine compartment and require a running engine to function. For me, its just an added layer of complexity I do not need. When four-wheeling I use my low gears and these jeeps are also really light. However, I'm sure there's people that just love their power-boostered ecj5 brakes.

On the other hand, I did convert to hanging pedals on the firewall. This is where project creep can come in. If you do this, and it's worth it, consider the clutch as well. Most people do a hydraulic clutch conversion...again you'll have to research this. After much consideration, I fabricated a mechanical system with a pull cable...although a little unorthodox, it works great, there's nothing to leak and it's been strong and reliable.

Pedals and master cylinders on the firewall will require some fabrication and reinforcing the firewall with a steel mounting plate on the engine side. Swinging pedals will put considerable stress on the firewall area. No two conversions are the same and there's many pedal-sets that can be made to work. Some challenges include working around your steering column, lining things up properly, making new brake lines, perhaps relocating some wires. Some of the many benefits are: Getting that exposed pedal assembly and MC off the frame rail to higher ground; MC is easy to service and access; The pedals do not move when the jeep is flexing out; pedals do not go through holes on the floor board.

If you're going for an SM420 swap (which is a great idea), then we'll assume you're wanting to do some four wheeling with this thing. So if that is true, the above upgrades are certainly worth it.

 

Friend just did the kit from Brennan Metcalf on the front of his early '6 with a 27 front. uses the geo tracker/suzuki sidekick disc that slides on, so no machining of the hub, or ordering a new disk brake hub. also no knuckle machining needed either. Order the bracket and then the rotor, caliper and pads local or cheaper on rock auto. happy with the kit and with the small calipers, can keep the stock master cylinder and have a good pedal.

Trackick Disc Brake Conversion Bracket, One Pair

 

This topic has been beaten to death. A quick search will turn up all sorts of old threads.

Front Disc Brake Tutorial

 

I did the Brennan's garage.com conversion as well...super slick set up!! My suggestion would be to use the 2000+ suzuki's vented rotors and matching calipers over the 1995 ones recommend in the bracket kit. The 1995 calipers require you use spacers included in the kit between the caliper and the bracket and non vented rotors. If you use the later vented rotors and calipers, they just bolt up without the spacers, and I think the thicker vented rotors are also a plus. The only modifications that need to be done is, your new rotors need to have the lug stud holes drilled out to half inch as the Jeep has larger lug studs than the Suzuki. The brackets will fit a Dana 25, 27 and 44 so they can be used on the front or rear. He has two kids available... one with 2 brackets for just the front or one with 4 brackets if you want to do front and rear. Your master cylinder will have to be upgraded for disc brakes. A pacer master is for disc/drum and has the lines coming out on the right side for frame mounted cylinders. All in all a very easy and slick conversion. Highly recommend.

 

Pacer as in AMC pacer...

 

If you go to u-tube and type in seven bar salvage, Jacob has a great u tube channel with lots of great Jeep videos. There is a video on there on doing the Brennan's garage disc brake conversion with links to the web site and part numbers for all the stuff neefed

 

the Metcalf disk brake conversion wont work on his 1974 flanged 44 axle, I thought

 

Desert Fox, has some kits for both front and rear.
https://www.facebook.com/profile.php?id=100057597543135

 

Richard Imholt formerly R&P 4 WD Parts Inc. Now R&P Early Jeeps
503-557-8911. He's been manufacturing them for decades and has multiple options for the front and makes them for the rear as well.