Outer Limits 4x4 Board

Ive just finished searching for information on what I need to swap my 94 stockman over to disc brakes, to no avail.

Maybe we could add something to the bible.

It has 1L diffs and I would like to swap the front to disc brakes.

How much of the diff assembly do I need?

Do I need to add a vac booster?

What other gear do I need and what else do I have to consider?

My 1.6L EFI Vitara motor arrives this week and I'd like to sort the brakes before I put it back on the road with the bigger donk.

If this has been discussed to death please point me in the direction of the existing thread.


cheers guys

if you are running regular 1lt diffs now, why not just grab another 1lt front diff with factory disc brakes? i know theyre cheap as chips down here..

A 94 Maruti (Stockman) came standard with front disc brakes. You should be having a good look at your vehicle.

Do you mean the rear??

Podge wrote:A 94 Maruti (Stockman) came standard with front disc brakes. You should be having a good look at your vehicle.

Do you mean the rear??

he is right.if you have discs already chuck on a brake booster before installing the engine.

I dont know about the 1litres, but i did a custom disc brake setup on my rear 1.3 WT axle if you have any questions.

joeblow wrote:

Podge wrote:A 94 Maruti (Stockman) came standard with front disc brakes. You should be having a good look at your vehicle.

Do you mean the rear??

he is right.if you have discs already chuck on a brake booster before installing the engine.

Suggest you read it again, as you've missed the point!! I didn't mention anything about the booster but as you mention, yes it would be a good idea (the difference between a 1.0l to a 1.3l with a booster, in braking is phenominal). However, the question/statement (in 2x sentences) was about swapping over to disc brakes, he is not saying that he already has disc brakes. So if jockrotten is wanting to swap over to disc brakes, what set-up is he swapping from if he wants to go to disc brakes??

Your right!

The mauriti should have disc front end.

Obviously they have been swapped at some stage.

I think i will chase up a price a whole new diff assembly.

Jock, are you saying that you have drum brake set up on the front?? If so that would be so bizzare! The only thing I could remotely think of is that somebody has replaced the front diff with either complete drum-drum diff out of Series 1 1.0l (81-8/83) or drums off the same model have been fitted. However, that would mean that somebody was after a really cheap fix.

i am going to go through every detail i remember as detailed as possible so if you dont care stop reading. I have done the conversion on a 81 1 litre and found it easy to do but expensive and seeing as it is only a SWB softy i wouldnt bother again and get a 1.3 which is what im donig. First thing that i suggest is to do it to a totally standard vehical, I mean totally standard unless you go all out like you are. This is because by the time you stuff around whith engineers (yes it needs to be engineered because you are modifying the fire wall, in adelaide anyway) and then he gos onabout the lift the big tyres blah blah blah it costs you 550 bucks just for him, then 71 bucks for the inspection and any defects etc they find. This sounds easy but is a major pian in the arse dealing with dicks. The next thing i suggest you do is become good mates with the wrecker or somewhere to get cheap parts from any disk brake sierra.

If you are still keen( think about it harder)

the list of things you need from the other sierra

-Pedal box
-boostrer
-master cylinder
-splitter below (this it will have 4 ports rather than three you have now and you cant make it work with what you have)
-i just got the lines to the front with the splitter but you can probably use your own

what you need to make-
-second brake line to the back(i used the charcolal canister route)
-braket to hold the top of the second rubber line next to original
-second rubber line next to the original
-bracket to hold the second line to the diff next to the orignial
-seperate solid lines to each wheel cylinder along the back of the diff

What you need to modify
The panel tack whelded to the firewall off the sj50 wont fit on the fire wall of the sj40 (i assume is the same as the muarti) because when alligned to the bolts of the steering shaft which remain constant the bend is too high, go figure. Also the clutch cable comes out lower on sj40 because it dosent have to clear the booster. So you need to cut along the bend on the sj40 plate once it is off the car of coarse. Then measure down the amount needed to be taken off the sj50 plate so the top sj40 (where the cable comes trough) to make it follow the firewall properly.Try to cut it square to make it all fit up and weld together, i used a flap disk to make it smooth and look pro . Tack it back on the fire wall you will now see that the booster want fit throgh the fire wall, mark it out exact and drill through with a hole saw. Now you will see the accelerator cable cant come through. Drill hole the same size as the fire wall not the plate, and cut down the accelerator pedal to suit. You will also see the bolts that hold the sj 50 pedal box dont exist in the fire wall so make them. Create any other holes i may have forgotten and fill any others not needed but the plate should cover most of them.

The clutch pedal will need the stop changed on the pedal box due to the lower point it goes throgh the fire wall. (it still clears the booster) so cut off the original and make one by test fit, (pretty sure its easy to see if it will work or not) but be carefull where you put it because the pedal could end up too high or too low. That should be it for the fire wall area any thing else shouldnt be hard in this area im pretty sure

The way i went for the rubber brake lines on the front was to modify the chassis mount point rather than the accual brake line. I enlarged the hole on the chassis and welded the bits on to make the later model spec rubber brake lines fit with the clip rater than the nut set up which i think may have been the better way to go. The rears need to opposite to each other like an x so make it accordinly. All i did for this is make the lines follow the charcol canister route. The charcol canister also needs to be inplace for the roadworthy inspection so something else needs to be done i have given up on this car so i havent come up with another way. The bracket at the top i made by straightening out the original one and drilling another hole, next to the other one. the bottom one i made out of 20x2 flat bar with two identical holes next to each other. then make the lines as i said. the wheel cylinders you need to get are the ones with the bleeder in them for both sides

i think that is about it i can remember any thing else but thats the bigger stuff any thing else will be little stuff to make it look better or easier etc hope it makes sense and helps

Super Zook, the model you have done the conversion would be much harder than a Maruti as your model didn't come from the factory with disc brakes, where as the Maruti did (however not with a brake booster). You've done the hard yards in doing a complete conversion with booster, most would just bolt on the disc brake set-up.

My '90 maruti has disc brakes on the front as standard. No booster.