Outer Limits 4x4 Board

hi im doing a rear disc brake upgrade on my hilux i will get roctoys brackets just need more info or pics of how people have hooked up there hand brakes any mods needed ect different cable also should i use just 80 master cylinder or with 80s booster as well

I havent done a disc brake rear conversion to my Lux, Im happy enough with my rear drums for now.
But from people I know that have done it, they say to fit a booster/master cyl from a vehicle that has disc rear, ie; 80series that has/had disc rear.

As for handbrake, its a Hilux, no matter what you do, it will still be crap.
The only way to have a perfectly working handbrake 100% of the time is to fit a trans handbrake, which arent legal.

I've done it - I'll try to get some pics up on my photo bucket soon (took heaps and been meaning to do a write up).

Initially I only got the 80 master as this is required for the reason Dudelux said - disc brake rear. If you are getting one from a wrecker make sure you get a 1" bore as the wrecker I went to came back with a 15/16", which is a Hilux one, unil I said it wasn't what I needed.

You don't need the 80 booster but I ended up changing that too as I wasn't that impressed with the upgrade with the hilux booster and the results were night and day. I'd recommend changing both but make sure you flip the 80 booster 180 (the vaccum hose should be facing down to the exhaust) as the piston inside the four studs that bolt to the firewall is NOT centred. It looks centred and it took me an hour of fidling to work out why it wouldn't bolt up.
I managed to make the handbrake work using the existing cable. I won't try and describe it as a pic will show it 1000 times better. The key to getting the handbrake to work is in adjusting the piston's in the suby calipers. They can be turned in and out on the threaded stud they fit to and this will determine the bite of the handbrake (again a photo will explain better). At least that's what I think - I'm yet to pull mine back apart to fiddle with it. At the moment my handbrake will hold if I'm stopped but if already rolling it won't grab.

Overall though the upgrade made a huge difference and would be well worth it especially with larger rubber fitted. I used to use the gearbox to help slow down but not I recon I could easily lock up the tyres. I'm only running 32" tyres.

Here's my Handbrake cable connection.. I also put the pin back through to secure it further. I know it will touch the shock but only while stopped as that's when it's under tension.


The Hilux and 80 boosters side by side


The offset of the piston that goes through the firewall


This is the inside of the Suby caliper where the piston screws in


The back of the piston that treads on to the above


I used my angle grinder wheel removal tool to thread the piston in


It's a tight fit to get the 80 master in if you have a Turbo. Note the 80 outlets on the master are opposite to a Hilux so it makes it easy to id.


Also the 80 master has a 1 on it where the Hilux is 15/16


This is how mine looked from above while I was fitting it and working out how to route / secure the flex line. I used the original Suby flex line as I got to remove the calipers at the wrecker.

ae86levin wrote:I've done it - I'll try to get some pics up on my photo bucket soon (took heaps and been meaning to do a write up).

Initially I only got the 80 master as this is required for the reason Dudelux said - disc brake rear. If you are getting one from a wrecker make sure you get a 1" bore as the wrecker I went to came back with a 15/16", which is a Hilux one, unil I said it wasn't what I needed.

You don't need the 80 booster but I ended up changing that too as I wasn't that impressed with the upgrade with the hilux booster and the results were night and day. I'd recommend changing both but make sure you flip the 80 booster 180 (the vaccum hose should be facing down to the exhaust) as the piston inside the four studs that bolt to the firewall is NOT centred. It looks centred and it took me an hour of fidling to work out why it wouldn't bolt up.
I managed to make the handbrake work using the existing cable. I won't try and describe it as a pic will show it 1000 times better. The key to getting the handbrake to work is in adjusting the piston's in the suby calipers. They can be turned in and out on the threaded stud they fit to and this will determine the bite of the handbrake (again a photo will explain better). At least that's what I think - I'm yet to pull mine back apart to fiddle with it. At the moment my handbrake will hold if I'm stopped but if already rolling it won't grab.

Overall though the upgrade made a huge difference and would be well worth it especially with larger rubber fitted. I used to use the gearbox to help slow down but not I recon I could easily lock up the tyres. I'm only running 32" tyres.

thanks for replys pics do speak louder then words

As I said, Im running the 80s booster and master cyl, but still have drum rear.
I never knew that I had to flip the booster, I just got a die grinder and egged the hole in the firewall a little bit, and it bolted up sweet.
Just another way it can be done.

Carry on....

[quote="DUDELUX"]As I said, Im running the 80s booster and master cyl, but still have drum rear.
I never knew that I had to flip the booster, I just got a die grinder and egged the hole in the firewall a little bit, and it bolted up sweet.
Just another way it can be done.

Carry on....[/quote thanks i did read your build up some where just need master from disc/disc

posted up some pics in original post.

Ive got the same but with only the 80 master not booster. My disc rear hand break holds on hills no problems. And it's just conected the same

What model Subaru do the calipers come from?

inbits wrote:What model Subaru do the calipers come from?

I GOT MINE OFF A 1988 L SERIES SUBARU 4WD WAGON HAVE A LOOK AT DESIGNFAB.COM, MAKE SURE THEY ARE IN GOOD NICK BECAUSE REBUILD KIT COSTS ABOUT $160 FOR BOTH CALIPARS, LOOK ON EBAY USA CHEAPER THEN WRECKERS