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Disc brake conversion odyssey

CoronetDarter

FBBO Gold Member
FBBO Gold Member
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Lincoln, CA
Let me start by saying, yes, this is another disc brake conversion how-to. There are scores of threads in this forum on disc brake selection and install (I know, during my research I probably read almost every single one). In addition Rick Ehrenberg's Disc-o-tech article is a must read (btw, he updated his original piece in the newest MA issue - Dec 14). And of course there's Google to fill in any gaps. So to all you members who have done this swap already, this is about the time you'll probably want to move on to a more stimulating topic. And to all you that have posted your brake swap experiences, thank you for the invaluable information that helped me do mine.

I have a 69 Coronet that had OEM power drums. I'm in the middle of a light restoration, the drivetrain has been removed and the car will be painted so as part of the brake conversion I dropped the K member and will upgrade the suspension at the same time. I will be keeping the rear drums. And btw, I am a shade-tree mechanic at best - I've done my share of driveway disc brake jobs but this is my first conversion.

There are dozens of conversion kit manufacturers and 10X as many distributors. I was on a budget so during my research I had eliminated the more expensive brands - Wilwood, SSBC, Baer, etc. Plus I wanted a kit that used repop Mopar parts so I could easily source replacement parts in the future. Lastly I was looking for at-the-wheel kits only because I'll be going with a Bendix style power booster with m/c and didn't want to purchase them in a kit to have them laying around my garage waiting for the car to be painted. The list of distributors is endless - YO, Classic Industries, Summit, PST, Pirate Jacks, POL, Mancini. If you're on a tight budget the cheapest kits I found were at Summit (free shipping) and Classic Industries (sku MD7785) less than $400 when you use their 20% off coupon. All these companies sell kits with the 11" rotor. I decided to go with the "big rotor" 11.75" that was standard on 78 Cordobas. If you decide to go with the bigger rotors the number of conversion kits drops dramatically.

I narrowed my search down to two companies. The first one is Wayne at RamMan. If you do nothing else, check out the how-to videos on his website, they're awesome. Wayne is a Mopar man all the way, he only sells Mopar brake parts (well, maybe some Ford on the side, but nobody's perfect :laughing7:) He's more expensive than the big supply houses but two things about his kits I liked: i) he doesn't sell the rotors, unless you want to buy his upgraded slotted/drilled set. As he says - why would I sell you a rotor that you can buy at any auto parts store in the country? I liked the fact that I could choose the quality of rotor to put in my car. I had planned on purchasing Raybestos slotted/drilled discs off of Rock Auto; ii) he sells RH and LH specific spindles for sway bar mounted cars. That way you're not swapping spindles from L to R and twisting up the flex hose. My Coronet doesn't have a sway bar so it was a moot point for me, but it's important if you have sway bars and have to mount the caliper on the rear of the spindle.

In the end, I went with Cass at Quality Body Shop Drivetrain - Dr. Diff. Cass is awesome - he picks up the phone every time and answered all my dumb questions via e-mail. He even e-mailed me a link from Moparts that showed his install with pics. I didn't go with RamMan simply because Wayne and I couldn't hook up over the course of a week and a half. I would call and leave a msg, he would call back the next day but then I was busy at work. He always returned my calls but after playing phone tag several times I called Cass and never looked back. I got the 11.75" slotted/drilled rotors and proportioning valve. His kit came with everything you need down to the cotter pins. The only thing you don't get is instructions - he assumes you have a FSM for guidance. Not having instructions was a minor inconvenience - the link he provided helped a lot.

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Nice write up. Please post the link you spoke of that Cass provided to the instructions on Moparts.

Thanks
 
All I can say is PirateJack.com if I had only gone there first as suggested 90% of my issues would have not existed. PirateJack for oem booster and MC
 
The install

From what I've researched, installation instructions can be spotty, and in the case of Dr. Diff nonexistent, so I'll attempt to guide first timers through the exercise. And again there's great information elsewhere on this site to fill in any gaps. After piecing together the components the conversion is actually pretty straightforward. There's only a few parts - the knuckles, dust shield, caliper bracket and the calipers themselves. Of course removing the old parts is a PITA - most of the bolts are torqued to over 100 ft-lbs and probably have years of grime built up. I took the K member down and disassembled everything off the car so it made access a little easier.

Before you start you must first check everything on the bench for fit and finish. On most kits the inner wheel bearings hang up on the spindle about half way down. I remember Hunt2Elk had this happen during his resto. When I asked Cass about it he said the knuckles are made to fit a range of models and years and some take a larger bearing. It takes about 10 minutes with 180 grit sandpaper to knock the spindle down to size. Cup the sandpaper in your palm and rotate it around the spindle for even coverage. Another thing - the rotors come with the races installed and the conversion kit comes with Timken bearings and races. Cass recommends swapping out the races. I had a brake shop swap the races, lube the bearings and install the rear seal; they were installing new bushings and pivot shaft in my LCA too so I got everything done for $80. I'm glad I did it because the original races that came with the rotor had scratches in 'em. Afterwards slide the rotor on the spindle and make sure it slides all the way back and spins freely. BTW, the conversion kit was made by The Right Stuff; the calipers came from NAPA auto.

I'm assuming you're familiar with disassembling the front end. Separate the knuckle from the upper ball joint, the lower ball joint from the outer tie rod (leave it attached to the knuckle), the LCA bolt, all the brake lines, flex hoses, etc. If you're keeping the original suspension parts then use a gear puller; if you use a pickle fork you're going to be replacing parts.

After you've checked everything and are good to go, the first thing to do is install the dust shield on the front of the knuckle. BTW, the knuckle and caliper bracket are cast metal; I painted them with Hi-Gloss POR-15 before installing. The pictures were taken before painting to show more contrast. If your car doesn't have a factory sway bar then the caliper mounts to the front. On the back of each knuckle is stamped a L and R. Naturally I figured the L was driver's side, but when I attached the dust shield it was obvious the caliper attached on the rear (there's only one way to attach the shield and bracket). Another call to Cass; he said ignore the L and R, the knuckles are interchangeable side to side. Whew!, one obstacle crossed.
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Next, install the bracket on the back of the knuckle. You're going to need a large Allen head wrench - don't know the size.
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Install the lower ball joint - if the ball joint hasn't been replaced in a while now's the time to get a new ones - they're cheap. I had to break out the Dremel and grind back a little of the dust shield to clear the ball joint bolts.
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Position the caliper on the bracket - this is a slider kit so there are no pins. The caliper and slider bracket (thin, shiny piece) attaches with one bolt. Bend the slider bracket tab downward to limit the travel of the caliper. The kit came with a rubber band as an anti-rattle guard - I installed it but it will probably only last about 1 mile before snapping. The caliper comes with the OEM style banjo fitting and stainless steel flex.
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Close-up looking down on the caliperIMG_1819.jpg
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As part of the suspension upgrade I got tubular UCA's from PST.
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Here's the finished install. Assembly was the reverse of disassembly. Don't forget to torque all bolts to factory specs. It's gonna be a while before I road test it. All I can say is if you're on the fence - go for it! Once you get into the install it's really not difficult.
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Thanks for the writeup, CoronetDarter. I'm at that stage right now. I bought my kit from Cass as well. My K is out, had it pwder coated, swapped to the tubular upper control arms also. I installed the spindles on mine. Gonna wait to install the rotors, calipers, etc until I slide the whole enchilada under my car (motor mounted on the K, waiting for the torque converter to install tranny). Also, don't know what to torque any of the bolts for my upgrade.

Was wondering how the rubber bands were installed on the calipers. Dont remember right off hand if I have it for the calipers to be mounted in the front or rear of the spindles. I did upgrade my original sway bar with a much larger than factory.
 
Thanks for the writeup, CoronetDarter. I'm at that stage right now. I bought my kit from Cass as well. My K is out, had it pwder coated, swapped to the tubular upper control arms also. I installed the spindles on mine. Gonna wait to install the rotors, calipers, etc until I slide the whole enchilada under my car (motor mounted on the K, waiting for the torque converter to install tranny). Also, don't know what to torque any of the bolts for my upgrade.

Was wondering how the rubber bands were installed on the calipers. Dont remember right off hand if I have it for the calipers to be mounted in the front or rear of the spindles. I did upgrade my original sway bar with a much larger than factory.

Thanks for the reply. You're a couple of steps ahead of me - I still have to figure out what to do with my engine. With the front sway bar you're probably mounting the caliper towards the back. As for the rubber bands, take a look at the close up pic of the caliper you can barely see the band wrapped around the aligning tab. I don't know if that's the correct way, it seemed good to me. The FSM has all the torque references; you should really get one if you don't already - I believe you can get copies on Moparts.com.
 
Nice set up. If you will please post his info. I will just have to get me a front disc brake set up also.
Thanks for the info.
 
Nice write-up and EXCELLENT photos. Thanks for taking the time to do that. Even though I already made my upgrades, my entire suspension is disassembled while I'm doing the motor swap since we removed the motor from the bottom, k-frame and all. Your photos may come in handy as I piece it back together.

By the way, a buddy of Dennis and mine (a local mopar guru) SWEARS by Cass at Dr. Diff for all kinds of mopar stuff.
 
Nice write-up and EXCELLENT photos. Thanks for taking the time to do that. Even though I already made my upgrades, my entire suspension is disassembled while I'm doing the motor swap since we removed the motor from the bottom, k-frame and all. Your photos may come in handy as I piece it back together.

By the way, a buddy of Dennis and mine (a local mopar guru) SWEARS by Cass at Dr. Diff for all kinds of mopar stuff.

Hey Dwayne,
It's been a while. How's your project coming along?
 
I recently completed a front disc conversion on my 70 RR using a kit from Dr. Diff.....Cass was very helpful on the phone.....so far so good.
 
That's good. Which rotor size did you go with? I haven't plumbed the distribution block yet, any issues?
 
I talked with Cass this evening and I ordered my new set of front disc brakes tonight. With The front mounted calipers, drilled and slotted rotors.The upgraded brake lines and new proportion valve also. I had just bought a new master cyl and adapter plate from him last week off of ebay. I had no idea he was the same guy until I read your post. I also called PST today and I ordered 11/16 tie rod ends and two new one piece sleeves with jam nuts. I have been looking to buy a kit but just have not done it. So Thank you for posting the photos and all the info as it has helped me and maybe some others. What a great place FBBO.
Thanks Again
 
You bet. That's a nice setup. This site has helped me countless times so I'm glad I was able to pay it forward.
 
Hey Dwayne,
It's been a while. How's your project coming along?

Making slow but steady progress working on it weekends only. I hope to get the engine bay in primer then paint by end of November. I need to remember to take some progress photos next time!
 
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