60 series rear disc conversion ?

[Cruza62]

Hi,
I've done some research on this topic and it seems that there are multiple combinations of doing this, but I cannot find anyone who has actually done it from start to finish that can safely say it's worth it.
I found one combination that seems to be working on an old hilux(i think) and this is what they used:
80 series non-ABS 2 bolt Master Cylinder
Prado booster (which is apparently the same as an 80 ?)
Discs using Subaru calipers (I don't know which ones - Leone?)
60 front discs as rear ?

And this is what was done to the front:
Kept the 60 discs but used slotted
Calipers off a IFS turbo diesel lux (which may be the same as 4Runner callipers ?)

Has anyone got any idea how this is done and has successfully completed it?
(Reason for this thread - I need to stop bigger tyres a lot better).
Thanks Ben

[midi73]

I have had my 70 series (same as 60) done. Didnt touch the front. Used the 80 master and booster I think. Had brackets made up for the back to put on WB statesman rear calipers (they have a handbrake, same as subaru does) I used the cruiser front rotors on the rear. The hubs had to be slightly machined so that the rotors would fit over. You can also use this same setup except you also use the cruiser front calipers on the back as well. With this setup you will need to do a transfer case handbrake setup.

[Cruza62]

Sounds good, how much of a difference has it made?
Ben

[midi73]

I actually dont know what it was like before. I bought the car and stripped it and rebuilt it. I did the convesion while I was rebuilding it, so I never drove it with drum rears. One really good difference though is that you dont get mud water etc stuck in the drums. Any mud etc is able to be hosed off.

[Cruza62]

Well as an example (considering my brakes at the moment are in pretty poor condition), I can't lock the brakes up in the dry with 31's, and when the 35's are on, the car just keeps on rollin'.
When you did your conversion did you have to make brackets up to hold the calliper? If so, have you got any pics so I can get an idea as to what I'm up for?
Thanks Ben

[midi73]

Well as an example (considering my brakes at the moment are in pretty poor condition), I can't lock the brakes up in the dry with 31's, and when the 35's are on, the car just keeps on rollin'.
When you did your conversion did you have to make brackets up to hold the calliper? If so, have you got any pics so I can get an idea as to what I'm up for?
Thanks Ben

Yes pullsd up pretty good with 35s. I had the brackets made up by a bloke who did them in bris. Was about 5 years ago now. was about $300 to make brackets machine hubs and supply calipers (second hand) from memory. Sorry no pics.

[flyology]

I am currently in the process of doing a 60 series rear disc conversion, using very similar parts.

However I am using 80 series rear hubs and GQ rear discs, which widens the track by approximately 70mm. (I am using IFS lux hubs on the front with disc spacers to widen the front by approximately the same). I am going to run 285 75 16 BFG AT's on 80 series GXL rims.

Calipers are subaru brumby, I dont know the exact year I believe 84 - 90? You need to get the calipers for the ventilated discs, (18mm) unless you use solid discs not sure what thickness they are.

I have an 80 series pre ABS master cylinder, and I also bought a Wilwood adjustable proportioning valve in case I need to adjust the brake bias, will probably help when I am loaded up and towing.

I have a set of 1993 turbo surf calipers for the front, not sure what piston size, either 43mm or 45mm, will measure them on my days off. (on nightshift at the moment)

I have had my caliper brackets cut with a water pressure cutter, had backing plates made up also to protect from rocks and debris being flicked up.

I have a spare set of brackets and backing plates (holes for the calipers are not drilled so you can choose your own) PM me if you are interested.

I found this site the other day when surfing the net, quite interesting and has some very useful info:

http://home.4x4wire.com/erik/4runner/brakes/

will post some pictures when I have finished my conversion

I believe Dumbdunce has done this rear disc conversion

[Cruza62]

Sweet!
So to get this right your only using the 80 series hubs to widen the track (I dont need to do that) so can I use the 60 hubs?

The brackets that you had water cut sounds like a goer, but to save the hassle of freight and that sort of thing, have you got the file (*.dxf or *.dwg) that they used to program the NC cutter with, I can use this file directly on the laser cutters we have at work (if it's 10mm thick or less) and simply make my own.

This also means there needs to be some welding to the diff housing right?

Thanks Ben

[flyology]

sorry, I dont have the program files for the brackets, I made a template out of aluminium and took it in for the place to copy.

My brackets bolt to the housing flange where the backing places bolt to (using longer bolts), but on the inside of the diff housing, so no welding.

Just remember what ever discs you use you will have to have calipers that are compatible in regards to thikness ventilated subaru brumby/leone calipers are for 18mm ventilated discs, cruiser front discs are 20mm, so may not work.

plus once you put discs on the rear you should use a compatible disc rear master cylinder.

[Cruza62]

Cool,
I think there are slotted rotors available for a 60, and they may be narrower? If not i'll have to use something else.
Ben

[Shadow]

Well as an example (considering my brakes at the moment are in pretty poor condition), I can't lock the brakes up in the dry with 31's, and when the 35's are on, the car just keeps on rollin'.
When you did your conversion did you have to make brackets up to hold the calliper? If so, have you got any pics so I can get an idea as to what I'm up for?
Thanks Ben

70% of your braking is in the front, if your front brakes arent doing there job your rear brakes are never going to be good enough to stop your car.

If you cant lock your front tyres with 31's on dirt, you have much much bigger problems than drum rear.

There is absolutely nothing wrong with the braking power of the 60 series, especially on 31's (actually smaller diametre than the vehicle was speced for).

I have a standard 60 series with 33's and I can lock all 4 wheels on bitumen. This was right after i had done a brake overhaul though.

Id suggest you start with a good brake overhaul, and then see how your braking is.

[midi73]

Well as an example (considering my brakes at the moment are in pretty poor condition), I can't lock the brakes up in the dry with 31's, and when the 35's are on, the car just keeps on rollin'.
When you did your conversion did you have to make brackets up to hold the calliper? If so, have you got any pics so I can get an idea as to what I'm up for?
Thanks Ben

70% of your braking is in the front, if your front brakes arent doing there job your rear brakes are never going to be good enough to stop your car.

If you cant lock your front tyres with 31's on dirt, you have much much bigger problems than drum rear.

There is absolutely nothing wrong with the braking power of the 60 series, especially on 31's (actually smaller diametre than the vehicle was speced for).

I have a standard 60 series with 33's and I can lock all 4 wheels on bitumen. This was right after i had done a brake overhaul though.

Id suggest you start with a good brake overhaul, and then see how your braking is.

I will second that.

[Sixty's Guy]

Well as an example (considering my brakes at the moment are in pretty poor condition), I can't lock the brakes up in the dry with 31's, and when the 35's are on, the car just keeps on rollin'.
When you did your conversion did you have to make brackets up to hold the calliper? If so, have you got any pics so I can get an idea as to what I'm up for?
Thanks Ben

70% of your braking is in the front, if your front brakes arent doing there job your rear brakes are never going to be good enough to stop your car.

If you cant lock your front tyres with 31's on dirt, you have much much bigger problems than drum rear.

There is absolutely nothing wrong with the braking power of the 60 series, especially on 31's (actually smaller diametre than the vehicle was speced for).

I have a standard 60 series with 33's and I can lock all 4 wheels on bitumen. This was right after i had done a brake overhaul though.

Id suggest you start with a good brake overhaul, and then see how your braking is.

I will second that.

I'll 'third' it. Mine locks up the wheels on bitumen wit 35z.

[Cruza62]

I expect that if I did a major overhaul to the braking system I would probably have the same braking capabilities as you guys, but the length of time that a set of rear discs would last in comparison to a set of drums makes it worth it. I do remember when the brakes on my thing were'nt too bad but as soon as I hit some mud a few times the rears simply cease to exist, I can reef the handbrake up at any point of a drive and it makes little or no effect at all on the speed I was doing.
The whole reason for doing this is to have a handbrake, some extra on/off road braking power and to not have to overhaul the brakes every time I go through a puddle.
Ben.

[GT60]

Anything happen with this mate...pics?

[flyology]

plus discs work a lot better than drums when you have to back down a track........

will have pics of my very similar conversion soon.

[Cruza62]

No pics yet and nothing happen yet...
But I've read a lot of stuff on another post! Maybe someone here can verify.
Are hilux front hubs (solid axle) the same as a 60?
I've got a disc brake catalog that says they have the same disc size etc ??

Anyhow, apparently the go is use a front hub off a hilux (which i presume is the same as a 60) and a Subaru Leone caliper. There is a guy that says he has done it with a 60 rear diff.... Which he has put in a hilux!!
And I have also read and I think I saw that an 80 series booster is the way to go because of its large bore etc. And it apparently fits. (Non ABS)
So it all seems to be non verified because no-one can provide pics !
Ben

[GT60]

Here's a thread from a US site, i know their rear axle setup is different they have semi floating axle's we have full floaters so not sure if everything else is the same?

There's plenty of other thread's about front disk upgrade's too.

http://forum.ih8mud.com/60-series-wagon ... parts.html

[RUFF]

Why not use 80 series rear Hubs,Discs and calipers and make a braket to suit the caliper?

[sambo]

When using patrol rear discs and subaru brumby calipers for a disc conversion on a 60series, how are people mounting the caliper.

1. welding a bracket to the diff housing.

2. Bolting it to the end of the diff.

the Patrol discs that i bought for this stick over the end of the diff, so if i bolt on the bracket. it will have to reach towards the centre of the diff to reach the caliper.

[flyology]

I am using:

80 series rear hubs
patrol rear discs
brumby calipers

caliper brackets that bolt on to the diff housing


on the front:

IFS lux hubs
60 series discs
IFS lux calipers (45 x 45 mm piston)
80 series m/cyl
80 series dual diaphram booster



I have all the parts, just need the time to get into it....

[Shadow]

I am using:

80 series rear hubs
patrol rear discs
brumby calipers

caliper brackets that bolt on to the diff housing


on the front:

IFS lux hubs
60 series discs
IFS lux calipers (45 x 45 mm piston)
80 series m/cyl
80 series dual diaphram booster



I have all the parts, just need the time to get into it....

do the ifs lux hubs offset your wheel mounting face further? increasing your wheelbase? Is this to match the increased offset on the 80 series rear hubs?

I think when all is said and done, your going to need a mod plate(qld) anyway, so i would definantly be talking to whoever is going to approve the mod before i did anything. Brakes are not something you can just easily mix and match ciomponents, especially disc brakes, if the master cylinder is not matched to both front and back circuits properly, there will always be a problem.

[flyology]

Have discussed the conversion with the local brake specialist/expert and he has given the nod.

Forgot to mention that I also have an adjustable brake proportioning valve for the bias between front and rear.

Yes, the IFS lux hubs (used with spacers to mount the 60 series discs) and 80 series hubs widen the track.

I will be running 80 series 16 x 8 inch GXL rims after the conversion is completed

[sambo]

people using a patrol disc and a subaru brumby caliper.

I sat my setup together the other day and the pad doesn't completely sit on the disc. obviously this is because the caliper was made for a smaller disc.

Are other peoples setups the same or is there just something wrong with mine.

[flyology]

This will be the same with all conversions using patrol disc and brumby calipers. However, (and a few people will scream here, but there is no need to) some conservative relieving/grinding of the caliper will have all of the pad making contact with the disc.

Only a few millimetres on the very outer edge of the caliper bracket should do it.

I believe that some people have used diahatsu disc instead of a patrol disc as it is smaller in diameter, havent seen it done or heard any feedback from using them though....

[Cruza62]

I'm a little confused...
I've got a DBA catalog and it's telling me that neither the brumby or leone have a vented rear disc, this means that its either not listed, drum or not vented. I just rang a Suby wrecker and he seems to think that the leone does'nt have a vented rear and the discs are paper thin. So this means that the calipers must'nt fit over the Patrol disc ????

What the?

What year Nissan Patrol?
What year leone/brumby?
Are they vented?
Please help

Ben.

[flyology]

The calipers used are from the front of the subaru, not the rear.

[Cruza62]

So if they are off the front what are these guys doing for a handbrake? Is'nt the hand brake on the rear?

If they are'nt having the handbrake on the wheels then why did'nt they just stick the 60 front hub on the rear, because they just bolt on?

Ben.

[bubs]

front hubs dont bolt on to the rear

I have done a couple by machining the rear side of a landcruiser hub to accept a hilux front disc. I then use hilux front callipers with a bracket which is welded on to the axle housing. These have all been on buggy's or comp rigs and never looked into engineering for the street. The only bit they wont like is the welded on calliper brackets.

Buddy

[Cruza62]

I've got my 60 in bits at the moment...
The front hub bolts onto the rear with the need of a 20mm spacer on the end of it so the axle does'nt go through the diff centre, the bearings are the same.

Are you talking about the hilux front onto the rear?

Ben.