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-   -   Tech-Installing rear discs on early Jeep Full Float D60 (http://www.ifsja.org/forums/vb/showthread.php?t=131704)

Gambler68 12-03-2010 12:05 PM

Tech-Installing rear discs on early Jeep Full Float D60
 
starting a thread for Tech Archives. I've searched all over the web and never seen a complete write up, so here we go.

The Victim: A 1972-74 narrow drum (staked) Jeep (which really is a dodge) Dana 60 8 lug Full Floater

The Supplies: Jeep D60 Rear Disc Kit from GubNI at NC4x4 forum, Pirate4x4 too I think. His is the least expensive kit, which includes 2 rotors (made in china, but look nicely machined), 2 rebuilt calipers, Brake Best pads, 2 brackets (decent machining but not perfect) bolts, 2 spacers, brakehoses. This application was 315 shipped, and they came very quickly via FedEx. So far, so good.


basic handtools, propane torch, Pb Blast, big block of wood.

The Attack:

First remove your axle shafts. Unbolt and slide out:


I used a 4" cutoff wheel and removed the Drum portion. Very easy and made the rest easier to do.


Soak the lugs and the inner face of the hub to the plate with PB Blast. I heated up the area first with a blue bottle first. Place on thick but soft block of wood and start tapping, alternating sides. When the hub face separates from the backing plate, slide a wedge in there. It doesn't take long to separate them.


Here you go. I'll be buying new lugs. Repeat on the other side.


I'll be updating this as I go.

scantar 12-03-2010 12:08 PM

Shweet! :thumbsup:

Gambler68 12-03-2010 05:31 PM

Hubs do not clear bolt heads for bracket and spacer to axle flange. With the nuts on the inside of the axle flange, they in NO way come close to fitting flush with the flange, because of the tube. Will require either grinding out a notch for each nut on the flange/tube weld/seam, or slicing off a good thickness of one nut face. Not sure if the spacer is an optional item, will try without it (it's maybe 1/8th in. thick steel).

One side's grade 8 bolts need to be replaced due to thread damage from having to use the bolts to make the bracket suck on..holes were mis-aligned enough the make this rather un-fun.

Gambler68 12-03-2010 06:03 PM

Managed to get other side on barely easier with the spacer, and the bolt heads on the hub side. Hub *almost* clears the bolt heads with the spacer on. Haven't tried with spacer off. Nuts would still requre shaving, or will have to notch into the flange neckdown a bit.

This would all be minor stuff if oh, I had a milling machine or a big drill press to address the minor layout problems, but for a joe with handtools.. :banghead:

I guess I'll have to put the discs on the shafts, re-install with the spacer on and grind some for the hub to seat, to see if the spacer is required for the calipers to line up with the disc, or if its there for the bolts to clear the hub or not.

The other possible idea would be to use the original bolts that held the backing plate on, but I don't think they are long enough...dunno, done for today. I know that much :)

RTFM 12-03-2010 06:13 PM

/Subscribed - as my 77 J-20 is getting the fronts and rears done in 2011.

Thanks for starting the thread.

Gambler68 12-03-2010 06:43 PM

Maybe it's different for later D60s, but this early one is being a beech. :cool:

v10sport 12-03-2010 08:29 PM

Quote:

Originally Posted by Gambler68
Managed to get other side on barely easier with the spacer, and the bolt heads on the hub side. Hub *almost* clears the bolt heads with the spacer on. Haven't tried with spacer off. Nuts would still requre shaving, or will have to notch into the flange neckdown a bit.

This would all be minor stuff if oh, I had a milling machine or a big drill press to address the minor layout problems, but for a joe with handtools.. :banghead:

I guess I'll have to put the discs on the shafts, re-install with the spacer on and grind some for the hub to seat, to see if the spacer is required for the calipers to line up with the disc, or if its there for the bolts to clear the hub or not.

The other possible idea would be to use the original bolts that held the backing plate on, but I don't think they are long enough...dunno, done for today. I know that much :)

Did you buy the kit from gubi on Pirate? If so, your bracket holes are probably drilled wrong. Mine were, none of the holes lined up. Turns out, the guy who makes the brackets for him miss drilled the holes. After I received the correct brackets, it bolted right up. He also sent me the wrong hub seals.

Elliott 12-03-2010 09:12 PM

Quote:

Originally Posted by Gambler68
starting a thread for Tech Archives. I've searched all over the web and never seen a complete write up, so here we go.

The Victim: A 1972-74 narrow drum (staked) Jeep (which really is a chevy) Dana 60 8 lug Full Floater.


I certainly wouldn't give GM that much credit. Dana built axles for all the manufactures and the BOM code on your axle will be for a Jeep if it came from a Jeep. :thumbsup: Thanks for putting this together. :cool:

Gambler68 12-03-2010 09:53 PM

Quote:

Originally Posted by v10sport
Did you buy the kit from gubi on Pirate? If so, your bracket holes are probably drilled wrong. Mine were, none of the holes lined up. Turns out, the guy who makes the brackets for him miss drilled the holes. After I received the correct brackets, it bolted right up. He also sent me the wrong hub seals.



Yup. Well that freaking sucks :mad: I actually did grow up in a machine shop..this stuff is off, but I can make it work, just have to wallow out some of these holes that are off. Oh well. Live and learn. I haven't checked the hub seals..they're cheap enough I don't mind if I have to replace.

v10sport 12-03-2010 10:17 PM

I couldnt get the seals locally. I had to order them. 37 bucks for both sides. Looks like you may have the correct ones. They use Ford brackets and redrill the 4 holes. Id PM him and let him know that your brackets are off. He needs to tighten his quality control on the brackets. When I got the correctly drilled brackets, I had to modify those so the caliper would bolt up. The left too much material in the ears of the bracket. Brakes work well now.

Gambler68 12-03-2010 10:28 PM

Well, that explains the 4 extra holes that definitely don't line up. None of that was mentioned. Thank you for sharing. :thumbsup:

Now..you didn't have any problems with the outside of the hub contacting with the bolt heads? Did you have grind anything for clearance (for the bolts). I will have to slice a face on each of the 4 mounting nuts, and bolt into them, then grind the bolt heads for the hub to fit in so the seal is firm against the spindle flange area it rides on. I don't want to grind either the hub or axle flange itself.

v10sport 12-03-2010 10:35 PM

My hub cleared the bolts

Gambler68 12-04-2010 12:56 PM

Cutting a face off the nut and forgoing a lockwasher seems to be the trick. Looks like the hub will clear. One hole needs redrilling. Enough room on the back to double nut em. Okay...

Gambler68 12-04-2010 04:53 PM

the bloody 4 hole spacer goes inbetween the bracket and the hub, doesn't it.

KaiserMan 12-04-2010 04:56 PM

I'd say return it. Sounds like it's all pretty messed up.

You see the write up J10MIke did on his dics? I don't recall him having issues.

I'd try for my money back and get the same kit he did.

Gambler68 12-04-2010 05:01 PM

Quote:

Originally Posted by KaiserMan
I'd say return it. Sounds like it's all pretty messed up.

You see the write up J10MIke did on his dics? I don't recall him having issues.

I'd try for my money back and get the same kit he did.



I'm too pissed to deal with returning it. I can use the brake hardware for the front.

I did just realize that I'd been putting the spacer inbetween the flange and the bracket, where it must actually be a spacer for the hub to press against. But I'm not sure the calipers will line up even. I'm going to give it another look before making a final call on it.

I was very clear what I had when ordering, that's all I can say right now.

v10sport 12-04-2010 05:07 PM

Spacer goes on, then bracket.

Gambler68 12-04-2010 05:28 PM

Quote:

Originally Posted by v10sport
Spacer goes on, then bracket.



not on mine :/ Did just try swapping to the outside, that would just raise the bolt heads out and into the hub. I had to grind the heads as it was so they didn't ride on the hub face.

Now, on yours, you have a 77 J20 rear..had the thick drums. Mine has/had narrow stake on drums (like..12x2 drums). I am thinking that's why the brackets on my year D60 FF have to be on the inside like these:

http://www.blackbirdscustomtrucks.com/index16.html (top of page)

What I'm (to say nicely) starting to get angry about is I was extremely clear on what I had, and was told the Chevy kit he sold would work as is. (for the round 4 hole flange 8 lug FF Dana 60 with stake drums).

Looking at the bracket, I'll have to cut an end off, narrow it about a 1/4" on the inside of the radius (through bolt holes like the Blackbird one), and bolt it on the back. Blackbird doesn't sell JUST their brackets, gotta get the drums with it, and it's 295 without calipers and pads, just the hardware, discs, and brackets.

So I don't know right now..glad I bought the kids presents before I got this. :banghead:

here's pics of the various ways I attempted it..the one with the caliper on is apparently the correct way..for a later D60, not mine.

pic above, is without spacer. Hub seats nice and clears bolts. Disc rides on the bracket and no room for pad, and the rather obviuos huge gap. Caliper bolt (top one) would not thread into the bracket, the supplied threaded hole was too small.







Gambler68 12-04-2010 05:52 PM

caliper bolt is buggered, prolly my fault. Oh, and all this is disregarding the bolt holes that are off enough the 3rd and 4th bolt dont come close to going in..but I'm pretty much at 100% certain these brackets don't work this way. Any comments, ideas, whatever are welcome. I haven't contacted the vendor yet till I know I'm right. I'm just coming to the assumption that I'm the first guy putting on discs on an early narrow drum D60 that ordered this kit, and finding it wont work as is.

v10sport 12-04-2010 06:13 PM

PM gubi. You're having all the same issues I had with the jacked up brackets. Dude probably cut them wrong along with the miss drilled holes.
My 60 wasnt staked, but had narrow drums on it. My hub does look different than yours. Regardless of the year, the flange is the same. The bracket is drilled wrong. Compare it to the bolt holes on the backing. You'll see the difference


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