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-   -   FJ40 Disc Brake Conversion (http://www.risingsun4x4club.org/forum2/showthread.php?t=7458)

RicardoJM 06-22-2008 10:53 PM

FJ40 Disc Brake Conversion
After researching various sources for new front cylinders for my drum brakes and realizing that it would be about $300, I decided to move in the direction of getting disc brakes up front. Drum brakes work just fine and if it were not for my odd build date and front cylinder sourcing issues I would have stayed with the drum brakes. As I tally up the conversion costs, they will definitely exceed $300, but I am looking forward to getting my 40 back on the road and having the "upgraded" brakes. :D

I looked into a couple of front axles from late 70s FJ40s and a couple of front axles from mid-80's FJ60s. As things turned out Thursday evening, I picked up an 60 series axle that was just a mile from the house. Here is is after we unloaded it from the 100. These things are heavy.


We pulled it out of a weed patch and it is a little dirty, but so far the only issue I found is one of the hubs must have taken a real shot to have caused the dial to break like this.


Looks like for some time someone used pliers to lock and unlock. The tell-tale signs of scoring are real clear on the cleaned up dial. I'm on the look out for a new dial (or hub) so that I can make it good as new. If you have one or can point me in the right direction to find one, I would appreciate it.

Today I started to strip off the parts that I will need for the conversion. Everything from the knuckles on out will need to be removed. This includes the steering arms. By the end of today I managed to get this far along on the tear down.


Lest, you think I am the slowest wrench in the club (ok - I likely am the slowest:snail:) I've also been using the parts the washer to clean them up as they come off. The cleaning of the parts takes the most time on this job but it is quite nice to be able to just toss them in and go to town getting all the grime and grease off.


Even with a washer, the calipers and rotors could not be cleaned up enough to go back on. Even if they would clean up, I will be much more confident in new parts for these components. From that perspective, here is today's bounty in cores.


I'll continue to post updates on my progress and will likely need some help with aspects of this before it is all said and done. My wheel bearing packing party experience yielded big dividends today. I was very comfortable with all of the wrenching needed to get this far.

Mendocino 06-23-2008 07:49 AM

Cool Ricardo:thumb: Disc brakes are good.:D

Cresso 06-23-2008 02:34 PM

I'm just about to button up this same exact swap, although I used a minitruck axle donor. I need to put in the pads and bleed the brakes and I'm done. I was pulling a few parts that I missed down at Pull-n-Save and saw good Aisin hubs on just about every 4runner down there.

wesintl 06-23-2008 03:18 PM

I have a dial you can have off an ifs rig. The dial is not raised (the thumb turn dealyo's) like the 60 ones but will work fine until you get a matching one or I think i have a pair and they can be matched. I'll look tonight

Rzeppa 06-23-2008 07:36 PM

Nice write up Ricardo and thanks for sharing! No kidding loaded axles are heavy, especially with the 3rd member still attached!

I'm like you as far as taking my time cleaning everything up as I go along. Makes for much easier re-assemble. Don't forget a good coat of rattle-can paint!

Glad the WBPP was helpful. My first one was to me too, and helps take the scary away from diving into stuff with little more than a manual and some hand tools.

The locking hub looks like normal rock-rash. Nothing a little cleaning up with a dremel won't cure :-)

You might consider pulling the 3rd and the sway bar off the axle just to make it a little easier to heft around. OTOH, you needed a new set of free weights to work out with anyway, right?

subzali 06-23-2008 07:46 PM

Jeff, did you see the crack in the dial of the hub?

I've gotten good at loading fully built axles out of my red truck with my dad's tractor and fork :D

Rzeppa 06-23-2008 07:50 PM


Originally Posted by subzali (Post 77790)
Jeff, did you see the crack in the dial of the hub?

It's just a flesh wound :-)

No I didn't - JB Weld? =-O

Okay, time for a new dial...

wesintl 06-23-2008 09:03 PM

Ricardo, I did a quick check in the garage and I could find any. I might have given my last set to TJ. If no one else posts up the yota yard usually has a box of em. I'm sure you can get one for reasonable.

RicardoJM 06-23-2008 09:25 PM

Wes, thanks for looking. Sounds like a trip to Yota yard or the Pull-n-Save is in my future.

This evening I pulled out both birfields and axles. After wiping the grease off of them I realized I did not pick up a pickle fork to separate the steering arm from the steering rod:o - guess I'll get the pickle fork tomorrow. My progress was limited to removing all of the nuts, bolts and washers and starting them soaking in the washer.

Tomorrow evening I should be complete with the tear down process and able to take the next couple of evenings to clean parts and rattle can the iron. Thanks for all the warm thoughts and help. :)

wesintl 06-23-2008 09:32 PM

I guess you don't need to save the tre but a bearing puller does a nicer job and doesn't ruin the boots. I have both if you need to use...

I'll do a more through look for you. I swore I had a least one. I'll let you know if I find it.

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