Posted by Gary d [162.158.74.102] on Sunday, May 07, 2017 at 17:16:33 :
Disk brakes 101
So after allot of research and discussions with some more google ings here is what I've come up with....
There are a couple different options when converting our Dana 44 from drum to disks. First off, nobody makes a kit, second most people think we're crazy to mess with these dodges. So option 1: 1979 Chevrolet k20 Dana 44...From the stub short shaft outward everything will bolt up with the exception of the u joints. The stub shafts that I bought from rock auto were thicker in the ear section than the original dodge, to I deburred it and smoothed it down just a bit. The unjoints which needs to be a "jump joint" nobody makes, large cap to small cap. So I took the large cap joints and machined down the shaft to accept the small cap and needle bearings, which works perfectly fine, the next time I do this though, I'll probably do some more research and use the small cap joints and put in larger needle bearings or make a round shim from titanium.
Another option is a 1980 jeep wagoner, again, use everything from the shafts out (same shafts as Chevrolet) but will give you 6 lugs instead of 8.
Some of the offsets in the backing-plates interfered with moving parts upon assembly so that's why I went with the k20 , but the jeep bolted up just fine as well.
Now an important part you don't want to forget is a 1/8" steel spacer placed between the housing and the hub, this I had a local guy with a waterjet make me a couple, that's the key to make the lockouts fit and work like a champ. The Chevrolet short shafts are approximately .6" longer than the dodge shafts. I rebuilt the complete front axle with new bearings,races, etc. I got most parts from Roy at quad4x4.com super knowledgeable guy on these danas. Rock auto had most of the parts about the same price but Roy put it together in a package. Now the rotors and Chevrolet stuff I got the best price from my local o Reilly auto parts store. The hardest piece to find in this whole puzzle is the disk brake caliper brackets, nobody that I found reproduces them I pickup up the Chevrolet Dana on Craigslist for $150 and the guy delivered it, the jeep Dana I got for $50 at a local junkyard.
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