If you own a Jeep XJ, you know how important reliable brakes are for your safety and off-road performance. Upgrading to rear disc brakes is one of the best improvements you can make.
But how do you make the switch from drum brakes to rear disc brakes without hassle? This guide will walk you through the Jeep XJ rear disk brake conversion process, highlighting key parts, installation tips, and what to expect. Whether you’re looking for better stopping power, easier maintenance, or a modern brake feel, this conversion can transform your Jeep’s braking system.
Keep reading to discover how to upgrade your XJ’s rear brakes step-by-step and enjoy smoother, safer rides every time you hit the road or trail.
Benefits Of Rear Disc Brake Conversion
Converting the Jeep XJ rear brakes from drum to disc brings several clear benefits. Disc brakes offer superior performance and reliability over traditional drum brakes. This upgrade enhances your vehicle’s braking ability and overall driving experience. Below are key advantages of rear disc brake conversion.
Improved Stopping Power
Disc brakes provide stronger and more consistent stopping force. They grip the rotor directly, which reduces stopping distance. This means your Jeep can stop quicker and safer in various conditions. Enhanced braking power is especially useful on steep hills or rough terrain.
Enhanced Safety
Rear disc brakes improve control during emergency stops. They reduce the risk of brake fade caused by overheating. Better brake response helps maintain vehicle stability, preventing skids or loss of control. Upgrading to disc brakes adds an important safety margin to your Jeep XJ.
Better Heat Dissipation
Disc brakes dissipate heat faster than drum brakes. This reduces brake fade during long drives or heavy braking. Cooler brakes maintain their effectiveness, ensuring reliable performance on tough trails or highway stops. Heat management is crucial for safe and consistent braking.
Easier Maintenance
Disc brakes are simpler and quicker to service. Inspecting pads and rotors is easier without removing the entire drum assembly. Replacing brake pads is straightforward and requires fewer tools. This lowers maintenance time and cost, keeping your Jeep ready for the road.
Key Components Required
Upgrading your Jeep XJ’s rear brakes to a disc system requires specific parts. These components ensure proper fit and safe operation. Each part plays a vital role in converting from drum to disc brakes. Understanding these key components helps you plan the conversion correctly.
Backing Plates And Calipers
Backing plates and calipers are essential for the disc brake system. Most builders use parts from Jeep ZJ or KJ models. These provide the correct mounting points and fit for the rear axle. Calipers grip the brake rotors to stop the wheels effectively.
Parking Brake Cables
The parking brake cables must connect the XJ’s handle to the new calipers. Stock cables usually do not fit this setup. Custom cables, like those from Crown Automotive, work well for this conversion. Proper cable length and routing are critical for parking brake function.
Proportioning Valve
A proportioning valve balances brake pressure between front and rear brakes. The stock valve may not suit disc brakes in the rear. A ZJ proportioning valve or a modified stock valve is ideal. This adjustment prevents rear wheel lockup during hard braking.
Wheel Studs And Rotors
Disc brake rotors are thicker than drum brake drums. This added thickness requires longer wheel studs to secure the wheels properly. Using the right studs ensures safe wheel attachment. High-quality rotors designed for Jeep XJ rear conversion improve braking performance.
Choosing The Right Conversion Kit
Choosing the right rear disk brake conversion kit for your Jeep XJ is crucial. The right kit improves brake performance and safety. It ensures a smooth fit without major modifications. Several factors affect your choice, like brand, fit type, and price. Understanding these helps you pick the best option for your needs and budget.
Focus on quality parts and compatibility with your vehicle. The kit should include all key components like backing plates, calipers, and parking brake cables. Proper brake bias is important, so a good proportioning valve matters. Wheel studs might need upgrading too, due to rotor thickness differences.
Popular Brands And Options
Many brands offer Jeep XJ rear disk brake conversion kits. Teraflex and Crown Automotive provide reliable kits with all necessary parts. SSBC-USA and Summit Racing also make popular options. ExtremeTerrain.com lists many kits with free delivery. Kits from Iron Rock Off Road and Armageddon Turbo & Performance stand out for quality. Each brand offers different features and levels of completeness.
Direct Fit Vs Custom Kits
Direct fit kits are designed for easy installation. They match factory mounting points and require minimal changes. Custom kits may need extra work and parts, such as modified cables or adapters. Direct fit kits save time and reduce errors. Custom kits allow more flexibility and sometimes better performance. Choose based on your skill level and project goals.
Price Ranges And Value
Prices vary widely for Jeep XJ rear disk brake kits. Budget options start around $460 but may lack some parts. Mid-range kits cost between $700 and $900 with full components included. Premium kits can exceed $1,000 and feature drilled or slotted rotors. Consider the value of included parts and warranty. Cheaper kits may cost more in labor or additional parts later.
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Preparation Before Installation
Proper preparation is crucial before starting the Jeep XJ rear disk brake conversion. It ensures a smooth installation process and improves safety. Taking time to prepare tools, workspace, and inspecting parts prevents mistakes and delays.
Clear organization makes the job easier and faster. Safety measures protect you and the vehicle. Careful inspection of existing brake components reveals any hidden issues. Each step matters to achieve a successful upgrade.
Tools And Workspace Setup
Gather all necessary tools before starting. Common tools include a jack, jack stands, socket set, wrenches, and brake cleaner. A brake line wrench helps avoid damage to fittings.
Prepare a clean, flat workspace with good lighting. Space around the vehicle should allow easy movement. Lay down protective mats or cardboard to catch small parts or fluids.
Vehicle Safety Precautions
Park the Jeep on a level surface and engage the parking brake. Use wheel chocks on front tires to prevent rolling. Always use jack stands to support the vehicle securely.
Never rely on the jack alone. Wear safety glasses and gloves for protection. Keep a fire extinguisher nearby when working with brake fluid or tools.
Inspecting Existing Brake Components
Check the condition of the rear brake drums and backing plates. Look for cracks, rust, or wear that could affect the conversion. Inspect brake lines for leaks or damage.
Examine the parking brake mechanism for proper function. Take note of any parts that may need replacement or cleaning. This inspection helps plan the upgrade and avoid surprises.
Step-by-step Installation Process
Converting your Jeep XJ’s rear drum brakes to disc brakes improves stopping power and safety. The installation process follows clear, manageable steps. Each step ensures proper fit and function of the new disc brake setup. Follow this guide carefully to complete your conversion smoothly.
Removing Old Drum Brakes
Start by lifting the vehicle and securing it with jack stands. Remove the rear wheels to access the drum brakes. Take off the brake drums carefully; they may need gentle tapping if stuck. Disconnect the brake shoes, springs, and hardware from the backing plate. Remove the old backing plates from the axle housing. Clean the area to prepare for new parts.
Installing Backing Plates And Calipers
Install the new backing plates designed for disc brakes. Bolt them firmly to the axle housing. Attach the disc brake calipers to the backing plates using the provided brackets. Make sure the calipers sit properly and move freely. Install the brake rotors onto the wheel hub. Use longer wheel studs if necessary for proper rotor fitment.
Attaching Parking Brake Cables
Replace the original parking brake cables with new ones made for the disc brake system. Connect the cables to the caliper parking brake lever. Route the cables along the frame to avoid damage and ensure smooth operation. Adjust the cable tension to allow the parking brake to hold the vehicle firmly.
Bleeding The Brake System
Fill the master cylinder reservoir with fresh brake fluid. Open the bleeder valves on each caliper. Pump the brake pedal slowly to push air out of the system. Close the valves once clear brake fluid flows. Repeat until no air bubbles remain. Keep the fluid level topped up to prevent air from entering again.
Adjusting The Parking Brake
Test the parking brake by pulling the lever inside the vehicle. Adjust the cable tension if the brake feels too loose or too tight. The parking brake should hold the Jeep on a slope without slipping. Make fine adjustments until the desired tension is reached. Check for smooth brake release after adjustment.
Master Cylinder Considerations
Switching your Jeep XJ’s rear brakes from drums to discs means checking the master cylinder. This part controls how brake fluid moves to the brakes. It must match the new system for safety and performance. Master cylinder issues can cause poor braking or pedal problems.
Master cylinder considerations include whether to keep the stock part or upgrade. You also need to check how the brake pedal feels after conversion. Proper pedal feel means better control and confidence when driving.
When To Keep The Stock Cylinder
The stock master cylinder can work if your new disc brakes match the old system’s fluid needs. If the cylinder is in good condition, it may handle the rear disc brake setup well. This saves money and time during the conversion.
Keep the stock cylinder if you notice no leaks or damage. Also, if the pedal feels firm and responsive, the stock unit is likely fine. Testing the brakes after installation helps confirm this.
Signs You Need An Upgrade
Soft or spongy brake pedal is a clear sign to upgrade the master cylinder. This means the cylinder is not pushing enough fluid to the discs. A hard or sinking pedal also shows it may fail soon.
Upgrading is necessary if the new brakes need more fluid volume or pressure than the stock cylinder provides. Also, a worn or rusty cylinder should be replaced to avoid brake failure.
Ensuring Proper Brake Pedal Feel
Proper pedal feel means the brake pedal is firm and stops the vehicle quickly. Bleed the brakes carefully after the conversion to remove air from the lines. Air in the system makes the pedal feel soft.
Use the right master cylinder for the disc brake setup. Test drive to check pedal response and stopping power. Adjust or replace parts if the pedal feels weak or inconsistent.
Testing And Troubleshooting
Testing and troubleshooting are vital steps after completing the Jeep XJ rear disk brake conversion. Proper checks confirm the system works safely and efficiently. Any issues found early can be fixed to avoid brake failure. Follow clear methods to test brake performance and maintain balance. Troubleshooting helps identify common problems and find simple fixes. This ensures your Jeep stops smoothly and reliably every time.
Brake Performance Checks
Start with a visual inspection of all brake parts. Look for leaks, loose bolts, or damaged components. Pump the brake pedal several times to build pressure. The pedal should feel firm, not spongy. Test the brakes at low speed in a safe area. The Jeep should stop straight without pulling to one side. Listen for unusual noises like grinding or squealing. Check the brake fluid level and top it off if needed. Regular performance checks keep your braking system reliable.
Common Issues And Fixes
A frequent problem is uneven brake pad wear. This may cause pulling or noise. Adjust caliper slides or replace worn pads. Brake fluid leaks can lower pressure and cause poor braking. Tighten fittings or replace damaged hoses. A soft or sinking brake pedal often means air in the system. Bleed the brakes fully to remove air pockets. Another issue is incorrect brake balance. This can result from a wrong proportioning valve or cable fitment. Inspect parts and swap or adjust as needed.
Maintaining Brake Balance
Brake balance ensures equal braking force on all wheels. It prevents skidding and uneven tire wear. Use a brake proportioning valve suited for rear disk brakes. Check the valve settings after conversion and adjust if needed. Test brake bias by applying brakes on different surfaces. Adjust cables and valves to keep balance stable. Regular maintenance helps maintain brake balance over time. Balanced brakes improve safety and driving control.
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Maintenance Tips Post Conversion
After converting your Jeep XJ rear brakes to disc brakes, proper maintenance is vital. The new system improves stopping power, but it also needs regular care. Following a maintenance routine helps keep your brakes reliable and safe. This section covers key tips to maintain your rear disc brakes effectively.
Regular Inspection Schedule
Check your rear disc brakes every 3,000 miles or after heavy use. Look for signs of wear on brake pads and rotors. Inspect brake lines and calipers for leaks or damage. Early detection prevents bigger problems and costly repairs. Keep a log of inspections to track brake condition over time.
Brake Pad And Rotor Care
Clean brake pads and rotors regularly with a brake cleaner spray. Remove dust and debris that can reduce braking efficiency. Replace pads once they are less than 3mm thick. Resurface or replace rotors if they show deep grooves or warping. Use quality parts to ensure long-lasting performance.
Parking Brake Adjustments
Disc brake conversions often need parking brake cable adjustments. Check cable tension to make sure the parking brake holds the vehicle firmly. Adjust the cable if the brake lever feels loose or too tight. Test the parking brake on a slope to confirm it works properly. Proper adjustment prevents brake drag or failure.
Upgrading Beyond Rear Brakes
Upgrading beyond rear brakes enhances your Jeep XJ’s overall stopping power. The rear disc brake conversion is a great start. Yet, improving front brakes, suspension, and brake fluid boosts safety and performance. Each part works together for better control and reliability on the road or trail.
Front Brake Enhancements
Upgrading front brakes complements the rear disc conversion. Larger rotors and high-quality calipers improve stopping force. Better brake pads reduce fade during long drives. These changes balance braking power front to rear. This prevents uneven wear and maintains vehicle stability.
Suspension And Wheel Upgrades
Improved suspension supports the upgraded braking system. Stronger shocks and springs handle rough terrain better. Stiffer suspension reduces body roll during hard braking. Upgrading wheels and tires increases traction and control. This setup improves overall driving confidence and safety.
Performance Brake Fluid
Using high-performance brake fluid is essential after brake upgrades. It resists heat and reduces brake fade. This fluid keeps brakes responsive in tough conditions. Regular fluid changes maintain brake system health. Choose fluid with a high boiling point for best results.
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Frequently Asked Questions
What Is A Jeep Xj Rear Disk Brake Conversion?
A rear disk brake conversion replaces drum brakes with disc brakes on a Jeep XJ. It improves braking performance, heat dissipation, and maintenance ease. The upgrade often uses parts from Jeep ZJ or KJ models for compatibility.
Why Upgrade Jeep Xj Rear Drums To Disc Brakes?
Disc brakes offer better stopping power and fade resistance than drum brakes. They require less frequent adjustment and provide improved parking brake performance. Upgrading enhances safety and braking reliability, especially for off-road or heavy-load use.
What Parts Are Needed For The Conversion?
Key parts include backing plates and calipers from ZJ/KJ models, custom parking brake cables, a proportioning valve, and longer wheel studs. These components ensure proper fitment and brake balance after converting from drums to discs.
Is Welding Required For The Brake Conversion?
No welding is typically needed. The conversion is a bolt-on upgrade using existing mounting points on the axle. This makes installation simpler and reversible if desired.
Conclusion
Upgrading your Jeep XJ with rear disc brakes improves stopping power and safety. The conversion uses parts from ZJ or KJ models, making installation straightforward. Custom parking brake cables and a proportioning valve adjustment ensure proper brake function. This upgrade offers better brake feel and easier maintenance than drum brakes.
Take time to follow each step carefully for the best results. Your Jeep will handle stops more confidently on and off the road. A rear disc brake conversion adds value and reliability to your vehicle.