AT-AT: Any trail, any time. :)
 

So I just got a '95 4.0L 2-door, I like it, and I already have a 4.8L LSx V8 and an Explorer 8.8" axle with a fresh Traction-Lock. My 4.8 is ready for an SM465, but I'm leaning toward the AX-15 for the Toyota g452 5.15:1 gearset as told here: http://www.pirate4x4.com/forum/jeep-...r-ax-15-a.html but otherwise the NV3500 was used with the 4.8, and Jeep used a HD version of the 3500 called the 3550, so this may be an easier bolt-together if the first idea proves too difficult. My SM465 is the 2WD version. If I go NV3500 I'll probably go NP241C. I had an idea for a NV3500 feeding a SM465 feeding a NP205. I may try this yet. I want to spin the 4.8 1900 RPM at 65 MPH.
But the 4.0 feels relatively strong, and the AW4 seems to be working well, so the V8 swap will wait. But the 4.0 doesn't need as much cruising RPM as it has. So probably tires first, once I find how to correct the speedometer. I need a tachometer ASAP.
Everyone makes a fuss about '95-up Explorers coming with discs, bit I'm unimpressed. I want to start with 16s, so 12.5" rotors will be an easy fit.
Explorers come with a micro-drum parking brake, but I prefer '76 Eldorado rear calipers. Like the '82-'88 WS6 Trans Am rear calipers, but the Eldorado version fits a thicker rotor.
I'm leaning toward modifying a new pair of WRX STI front rotors, but they may require 17" wheels, as they're 12.835". But back in the '70s, Police Caprices had 12" rotors in 15" steel wheels, and 'vettes had 12" discs in 15" aluminum wheels, so I may not need 17s. So I need a wheel, a rotor, and a caliper for a mockup.

Napa's website is the best resource I've found for searching brake rotors by dimensions, and I just found a likely candidate, so this update is mostly for my future reference. But Napa doesn't specify applications, so no getting the same rotor cheaper from www.rockauto.com.
The '77 Eldorado calipers came on 1.21"-thick rotors with a height of 2.28"
NB48880377 is 1.179" x 1.23", is 5x4.5", is 12.42", is for the front of something offered from '06-'14, and is $66.49 ea. But the center hole is 2.29", which will have to be machined out to 2.79".
'07 Mustang GT front rotors are only $27 ea, and are 12.43", and are 1.18" thick with the 2.79" center hole, but are only 1.90" tall, which might not get the wheels out past the calipers without spacers, and wheel spacers are illegal here.
The '06 WRX STI rotors are only $15 each, are 2.075" tall, 1.18" thick, with a 2.28" center bore. These are 5x4.5", as are the Mustang rotors.

Matching fronts? Stock is 11" with a 3.23" height, NB4886838 is 12.6" with a 3.23" height. After designing a now-functional big brake upgrade for a second-gen RX-7, I know height is the important spec. I'll be making my own caliper adapters, so the extra thickness and diameter are both ok, I can't keep stock front calipers, and don't want to anyway. They're floating single-piston, I want fixed 4-piston.
So, these have a 5x112 lug pattern, but can be drilled for 5x4.5", and the center hole needs enlarged from 2.64" to 2.84". These are 1.18" thick, and $66.49 each.

1.18" is 30 mm, and '90 300ZX turbo came with aluminum 4-piston calipers for 30 mm rotors, and 91-92.5 '96 turbo and non-turbo were same , '93-'96 were iron, but still 4-piston for 30 mm. So finding a donor at Pick-N-Pull should be easy.

Here's the original thread that inspired my idea to put a NV3500C in front of an SM465. http://www.pirate4x4.com/forum/gener...smissions.html
My first problem is that my SM465 is the 2WD version.
Everyone else that tried this broke the input shaft on the rear trans, because they didn't use either an SM465 with the 1.5" input shaft upgrade, or something even stronger. The 1.375" Cummins input for the NV4500 isn't strong enough.
Then the NP205 is the minimum t-case for strength. Nothing less will hold. And it must be the later 32-spline-input NP205, the 10-spline input will fail. Forget a doubler, that's what the rear SM465 is for.

I'm beginning to think y'all are just here for pics, not innovative tech.

Allot of numbers in a huge paragraph. Lots of "forum crawlers" wont put in the effort to read it. Try bullet points and grouping ideas with headers.
If i understand right, you want to run the 4.0 and AW4 for now, but eventually a 4.8? v8 swap with a sm465.

Are you building a rockcrawler? what kindof power does the 4.8 put out?
For ease of parts, i would stick with an AX-15. I think you are overplanning the brakes. The explorers tip the scales at just over 4,500 and their brakes work fine. your not stopping a 7,000 lb truck, were taking about a 3,700lb tin can. i would spend the time and money allocated to your brake conundrum to frame boxing, suspension and gearing. if that 4.8 makes any kind of torque, your weak link wont be the transmission and transfer case, it will be the axles and drivelines.

just my 2 pennies

If you are up for the fab work, go for it, but it seems like allot of unnecesary work.

Keep up the ideas...looking forward to the progress!

Needs MOAR pics!

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