Preface: From reading numerous threads I assume folks are going to ask why I didn't go with Toyota parts as many suggest here. Simply put, these parts were readily available and I had the tools to make the conversion happen.
I know this has been covered here before, but I thought I might share my experience of putting disc brakes (Chevy rotors and calipers) on the front of my 1975 FJ40 in case it helps others. I decided to see if I could do this conversion a bit cheaper than buying the complete JT Outfitter's kit and sourcing separate parts and doing some labor myself. I'm posting here for other who don't mind doing a little work themselves and might want to price out the parts separately.
First I started with the JT outfitter's caliper bracket. I believe others here on the forum sell this bracket as well.
Front Disc Conversion Brake Brackets for Toyota Land Cruiser FJ40 FJ45 - JTOutfitters
$149.95
I made a list of several part numbers from many of the threads here on the forums to help sort through what I would need to buy. My notes are as follows:
Front Disc Conversion:
Calipers:
18-4071,72 (monte carlo) fronts
Autozone Part Number: C161
Alternate Part Number: 90125
Rotor:
88-91 GM, 1/2 ton, K series 1
specifically 1990 CHEVROLET K1500 PICKUP 5.0L 305cid V8 TBI
machine center hole to 4.175”
Raybestos - 5977
Napa # 85977 for rear rotor if wanting thin rotor
I also took notes on the rear conversion in case I decide to tackle that later, but this thread will focus on the front's only.
Rear Conversion:
Calipers:
from a 85 monte carlo autozone #p4071 68.31
front not rears!!!
Caliper Brackets:
brackets, rotors steve aka POSER 161.00 plus shipping
Proportioning Valve:
wilwood proportioning valve jegs# 555-63020 34.99
Wheel Studs:
as your stock ones will be short, to short for comfort for me. DORMAN 44mm long . stock is around 38mm, part # is 610-265 10 peices to a box and they are M12-1.5X44.8MM.
dorman wheel studs, part # is 610-265 $1.99 a piece at oreilleys
Napa part number for longer studs #641-2196
Longer wheel studs - Dorman 610-414
Brake Hoses:
Raymold brake hoses - 4536825
brake hoses for calipers autozone 70770 15.99 x2
Part Number: 70770
Alternate Part Number: H381115
$12.99
Banjo Bolt(s):
autozone #13940 4.99 x2
part number 13940
New Part Number List for Front Conversion:
Then I started cross referencing part numbers on Rock Auto so i could figure out what to purchase. I came up with the following. I'm sure many of you will be able to further cross reference these parts to find sources to be able to purchase the parts you need if you decide to go with Napa, Autozone, etc....
Rock Auto:
Caliper: A-1 CARDONE 184071 Qty:1 (18-4071) $ 35.23
Caliper: A-1 CARDONE 184072 Qty:1 (18-4072) $ 35.23
Banjo Bolt: DORMAN 484205 (13940) Hydraulic Hose to Caliper / $ 2.10 (you need if the calipers do not include these, but the calipers I ordered did come with them
Hydraulic Hose: RAYBESTOS BH36825 Qty:2 $ 19.14
Rotors: RAYBESTOS 5977R Qty:2 for $ 45.58
Brake Pad Kit: RAYBESTOS SGD154M Qty:1 $ 9.86
I already had an updated brake booster, master cylinder, and proportioning valve so I was set to start work. The parts came in and I started to mock things up to see what else would need to be done.
The caliper mount is a very nice piece. Many had commented on needing to grind the caliper to fit the bracket so I was glad to see that the caliper fit without grinding. That said, it would need to have a small area ground away to clear the birfield/axle housing, so I jumped the gun a bit when I saw the initial mockup.
The Chevy rotors need to be opened up a bit to fit the Toyota wheel spindles. I happen to have a small machine shop and since my lathe has too small of a swing to accommodate the rotors, I decided to mount the rotors in my CNC mill and machine them to size. As noted above in the rear conversion the insides need to have the center hole machined to 4.175”.
I ended up just profiling the rotors rather than pocketing to make the process quicker on the mill.
To be continued...
I know this has been covered here before, but I thought I might share my experience of putting disc brakes (Chevy rotors and calipers) on the front of my 1975 FJ40 in case it helps others. I decided to see if I could do this conversion a bit cheaper than buying the complete JT Outfitter's kit and sourcing separate parts and doing some labor myself. I'm posting here for other who don't mind doing a little work themselves and might want to price out the parts separately.
First I started with the JT outfitter's caliper bracket. I believe others here on the forum sell this bracket as well.
Front Disc Conversion Brake Brackets for Toyota Land Cruiser FJ40 FJ45 - JTOutfitters
$149.95
I made a list of several part numbers from many of the threads here on the forums to help sort through what I would need to buy. My notes are as follows:
Front Disc Conversion:
Calipers:
18-4071,72 (monte carlo) fronts
Autozone Part Number: C161
Alternate Part Number: 90125
Rotor:
88-91 GM, 1/2 ton, K series 1
specifically 1990 CHEVROLET K1500 PICKUP 5.0L 305cid V8 TBI
machine center hole to 4.175”
Raybestos - 5977
Napa # 85977 for rear rotor if wanting thin rotor
I also took notes on the rear conversion in case I decide to tackle that later, but this thread will focus on the front's only.
Rear Conversion:
Calipers:
from a 85 monte carlo autozone #p4071 68.31
front not rears!!!
Caliper Brackets:
brackets, rotors steve aka POSER 161.00 plus shipping
Proportioning Valve:
wilwood proportioning valve jegs# 555-63020 34.99
Wheel Studs:
as your stock ones will be short, to short for comfort for me. DORMAN 44mm long . stock is around 38mm, part # is 610-265 10 peices to a box and they are M12-1.5X44.8MM.
dorman wheel studs, part # is 610-265 $1.99 a piece at oreilleys
Napa part number for longer studs #641-2196
Longer wheel studs - Dorman 610-414
Brake Hoses:
Raymold brake hoses - 4536825
brake hoses for calipers autozone 70770 15.99 x2
Part Number: 70770
Alternate Part Number: H381115
$12.99
Banjo Bolt(s):
autozone #13940 4.99 x2
part number 13940
New Part Number List for Front Conversion:
Then I started cross referencing part numbers on Rock Auto so i could figure out what to purchase. I came up with the following. I'm sure many of you will be able to further cross reference these parts to find sources to be able to purchase the parts you need if you decide to go with Napa, Autozone, etc....
Rock Auto:
Caliper: A-1 CARDONE 184071 Qty:1 (18-4071) $ 35.23
Caliper: A-1 CARDONE 184072 Qty:1 (18-4072) $ 35.23
Banjo Bolt: DORMAN 484205 (13940) Hydraulic Hose to Caliper / $ 2.10 (you need if the calipers do not include these, but the calipers I ordered did come with them
Hydraulic Hose: RAYBESTOS BH36825 Qty:2 $ 19.14
Rotors: RAYBESTOS 5977R Qty:2 for $ 45.58
Brake Pad Kit: RAYBESTOS SGD154M Qty:1 $ 9.86
I already had an updated brake booster, master cylinder, and proportioning valve so I was set to start work. The parts came in and I started to mock things up to see what else would need to be done.
The caliper mount is a very nice piece. Many had commented on needing to grind the caliper to fit the bracket so I was glad to see that the caliper fit without grinding. That said, it would need to have a small area ground away to clear the birfield/axle housing, so I jumped the gun a bit when I saw the initial mockup.
The Chevy rotors need to be opened up a bit to fit the Toyota wheel spindles. I happen to have a small machine shop and since my lathe has too small of a swing to accommodate the rotors, I decided to mount the rotors in my CNC mill and machine them to size. As noted above in the rear conversion the insides need to have the center hole machined to 4.175”.
I ended up just profiling the rotors rather than pocketing to make the process quicker on the mill.
To be continued...