FJ40 Disc Conversion

[fireflyr]

Finished the disc conversion. Poser brackets in the rear and JT Outfitters brackets up front. Monte Carlo calipers and chevy 1/2 ton vented discs on all 4 corners. The biggest problem was figuring out all of the different types of fittings that had to be used.
The master cyllinder came from Man A Fre: 3 bolt to 2 bolt adapter with a Wilwood dual circuit mc with a proportioning valve installed on the rear lines.

The install was pretty straight forward. The hardest part was milling (sanding) off 4mm from the front hubs so the discs would fit. I used a stationary belt sander.

I also had to purchase 4 new welded wheels from Toyota. The riveted wheels wouldn't clear the calipers.

 

[Viggen]

Nice. How did you like the rear kit? I am looking at doing this on my 60.

 

[1911]

Good work. My disc conversion has been the best improvement for driving my 40 yet. So nice to have it stop straight and be able to lock up all four wheels, without the constant maintenance of drums.

 

[fireflyr]

Nice. How did you like the rear kit? I am looking at doing this on my 60.

It would be alot easier on the 60 than on my 40. You can buy the brackets and discs from Steve on MUD ($160), then source the lines ($30), Banjo Bolts ($16) and calipers (loaded $80) from Autozone. It will cost $200 less than the kit. I had 9mm line fittings but all of your stuff should be 10mm which is still available. I think the brake lines (Autozone part # 70770) will bolt right on.

Your hardest part will be cutting off the brake backing plate, or removing the axles (I did this). I think you'll have to run a proportioning valve and remove the residual valve if there is one installed.

 

[TangoBlue]

WOW! That is one good looking 40. Great job! I'm a sucker for 464.

 

[Grease Cruiser]

Nice. How did you like the rear kit? I am looking at doing this on my 60.

Not really worth doing on a 60 since you will lose your parking brake.

 

[Viggen]

I didnt realize that. I obviously want to keep the hand brake but would like discs in the rear. The stopping power is a plus but Ive also had the discs help me down the trail once. I was wheeling my XJ (4.7 stroker, 8.8" Ford rear) and snapped a shaft once. I didnt have a spare with me (obviously wasnt expecting to break one as the trail wasnt that hard but the motor was a bruiser). Being a C clip rear axle, if I had drums, the shaft/ wheel wouldve walked right out. The caliper was able to "hold" the wheel and axle in place until I got to a place where I could get off the trail and come back with a new shaft.

So, what do people with disc brakes in the rear of their 60 do for handbrakes?

 

[1911]

So, what do people with disc brakes in the rear of their 60 do for handbrakes?

There are GM calipers for a Cadillac model that have integral e-brakes, that fit the common conversion brackets, but by all accounts they're not ideal nor foolproof. A lot of info on these if you look over on IH8MUD.

 

[Klierslc]

Could also use a line lock...

 

[Hltoppr]

This, IMO, is one of the best upgrades one can make on an older 40 series!

-H-