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Disc Brake Conversion Options / Suggestions 68 Cj5

Discussion in 'Early CJ5 and CJ6 Tech' started by Phillykaiser79, Nov 12, 2021.

  1. Nov 12, 2021

    Phillykaiser79 New Member

    Lincoln University
    Jan 7, 2019
    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.
  2. Nov 12, 2021

    truckee4x4 Grant Kaye 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Truckee CA
    May 30, 2008
    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.
  3. Nov 12, 2021

    Oldpappy A.C. Fults - Curmudgeon at large 2021 Sponsor

    East Tennessee
    Feb 8, 2021
    There is a very long thread on disc brake conversions on the CJ2A forum that would be worth a read.
  4. Nov 12, 2021

    GillaFunk I'm the Dude, so thats what you call me. 2022 Sponsor

    Graeagle Calif...
    Sep 26, 2019
    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.
  5. Nov 12, 2021
    scott milliner

    scott milliner Master Fabricator

    Seattle Wa.
    Dec 17, 2002
    My 73' Dana 30. I had to have the back side of the hubs machined to except the disc's.
  6. Nov 13, 2021
    Sierra Bum

    Sierra Bum Member

    The High Sierra
    Oct 23, 2017
    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.
    Last edited: Nov 13, 2021
  7. Nov 15, 2021

    fourtrail Built not Bought

    Jan 24, 2004
    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
  8. Nov 15, 2021
    garage gnome

    garage gnome ECJ5 welder 2021 Sponsor 2020 Sponsor

    Western MA
    Jun 19, 2009
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