I have a 90 cherokee with a Dana 35 in the rear end. I would like to do a swap from the drum brakes to Disc. My local auto wrecker has them for $50 a side. A couple of questions. 1. Will the Disc assemblies from a 96 Grande Cherokee fit my rear end 2. Do i need to change the master cylinder. 3. Does the original E brake cable hook back up or do i need new cables. 4. Do i need to modify the rear end or brake assembly in any way.
I had thought about replacing the entire rear end with brake assemblys already attached but the auto wrecker in my kneck of the woods wants 900 canadian for a used rear end.

 

The Grand parts will work fine on the XJ, and you shouldn't need to change the master cylinder at all. If the breaks feel spongy than change the master but you should be fine. As for e-brake, it should work fine with the stock XJ stuff. I've done the swap onto a TJ with out any mods..

 

Did you ever do the swap? Just wondering what parts worked because I'm thinking about doing a swap too!

 

Most if not all convesions that I've found have you needing to remove the rear axles to complete the conversion. I found a site where the axles don't need to be removed. Maybe you avid mechanics can give your opinion on the conversion method described here:

http://www.geocities.com/xj88driver/xjreardisk.htm

 

I am looking to do this also...and from my research most require pulling the axles. I have a D35 with C-clips and it should go ok. I have located a few parts but no complete donors.

 

When looking for Grand Cherokee donors should I be looking for rear disc brakes only? I think the rear will be the only ones that are set up for the emergency brake cable. I'm thinking I will get all but the calipers because I want to go with a new or rebuilt set from the parts store.

 

My 1989 Has the D35 also. I'm worried if I start pulling the D35 apart to remove the axles I'll be in for a domino effect of repairs! Maybe if they go bad when pulling apart they were about to go bad anyway? Damned if you do, damned if you don't!

 

look for a Grand with disc brakes and D35 axles ......make sure you get everything you can including the E-brake parts.

Need:
Back plate
caliper mounts
e-brake shoes and parts
calipers/rotors
brake lines (including steel line)

options you can do:
New brake lines
New calipers/rotors

 

Not sure if yours is a C-clip or if it has to be pulled with a puller. Either way you can plan for a few problems like brake lines being seized and hard to remove and getting parts off of the donor. Either way will be a good time to make everything right and service your rear axle.

 

Thanks for the insight! My thinking of the conversion came when I found my rear wheel cylinders to be frozen and a rear brake line from the actuator to the right rear wheel broke during my front brake bleeding. I figured if I have to replace a bunch of the rear brake components (lines, shoes, cylinders & hardware and one drum) during my rebuild why not do a disc conversion!!!

 

the zj backing plates are net a direct swap either you need to redrill the mounting plates to work with your axle the d35 is as close as it gets for a direct swap the 8.25 and d44 need a lot of work to make the backing plates work. take your time read some swap post and take your time

 

To remove the backing plate I'll need to pull the axels on the donor vehicle anyway so why not do my own! I get to practice on the donor vehicle/vehicles first!!! Do you know what year Grand Cherokee D35's are sure to have the clips?

 

Here's the link to my disc swap on an XJ D44 to Ford 8.8 discs in my build:
https://www.cherokeeforum.com/showth...?t=4784&page=3

Not sure how the e-brake fuctions on the Grands but I had to do a little modification to get the Ford ones to work with XJ cables. You should not need to replace your master cylinder or booster, however it is advised to switch your porportioning valve out with the one on the zj you get the brakes from so that you have proper braking presure at all wheels. You will need longer wheel studs. Many people over look this fact and try to get by with the old ones but they will be to short for your new brake setup as discs are thicker than drums. Just get some for a ZJ with discs and you'll be good to go. You will also need to get new lug nuts to as they are a diffrent thread.
You do not need to pull the whole axle to do this swap and infact it would be easier if you didn't. Just pull the shafts, put on your "new" / modifid hardware. No need to pull the whole thing since your just modifing the axle flange parts.

On a side note doing this swap on a D-35 is worthless unless its a DD that does not see trail use. Swap the rear end out for a 8.25 29 spline, XJ D44, or Ford 8.8 then feel free to do the disc swap so you don't waste your money on an axle that will eventually need to be replaced. just my 2cents...

Good luck with the swap though if you pursue it. I had a lot of fun doing mine and I'm very pleased with the results.

 

I believe and someone can correct me...but all Grands with rear disc should have a c-clip rear axle. Someone chime in if I am wrong.

 

Desertfox1023 Thanks for your insight! I won't be using mine on a trail. Thanks for the tip on the longer wheel studs!

a1racer I have a nice drill press so I'm eager to redrill!

bsljacques I looked in my 1987-1989 Chilton's and it says I need a puller for my axles. The nice thing about my manual is I usually don't need to figure out if the repair pertains to my year!