A common problem with the ZJ is the grooves that wear into the caliper mounting brackets on the front brakes. It causes the pads to wear unevenly and in my case, make the pads stick to the rotors occasionally. What is the best fix? I can TIG weld them with a Nickle content rod and flush it to the original shape. It is Cast Iron...bad things are known to happen when welding Cast. Thus the Nickle content of the filler rod. I can upgrade to WJ brakes. If If I can find the new part, I could just replace the old worn parts. Another option I am considering is Getting a XJ HP Dana 30 for the front.....do they have the same problem? And more importantly is the gear ratio the same as mine? Are the shock and spring mounts the same as mine? In other words, will it bolt right in? My ZJ has Anti Lock brakes....I know that might be an issue too.
Where is the best place to find new mounting brackets? How much does the parts cost. Is it best to upgrade to WJ brakes monetarily?
Please give me the best choice....I am on a budget and the new pads are out of the groove "for now". Thanks guys.

 

Mounting bracket is part of the knuckle. Replace the knuckle and you should be fine for another 100,000 miles. Also, I believe the knuckles are forged, but are easily welded and ground down for reusing.

 

We were assuming that they are cast. Forged steel is easily welded. Thank you. How much, and where can I get the new parts just in case? I am definitely on a budget and I have a nice Miller TIG machine and plenty of experience, so I am going to go that route first. I was just very Leary of welding cast on anything to do with brakes.

 

I welded mine, so I dont know how much.

 

So, you haven't had any issues since? Sounds like I just found out what I'm doing today. Thanks..... Have a great Labor Day.

 

weld away...no worries, just use a straight edge when grinding so that the pads dont bind.

 

I will make it look like it was never there. Thanks again.

 

Rest assured that the knuckle is forged and being an integral part, the bracket is also.

WJ brakes have a removable caliper bracket because it hangs over the rotor and must be removed to remove that. In order to use the WJ brakes on a ZJ, you have to buy or steal WJ knuckles. Then the wheel bolt pattern is 5x5, not 5x4.5. The tread width is wider on the WJ, so you can't use WJ axles in the rear end to change the bolt pattern. Also the axle bearings are different from the ZJ.

You can use WJ wheels on the front and ZJ wheels on the back, but they MUST be the same diameter. WJs have 16" wheels to clear the calipers or aftermarket 15's with less backspacing.

Basically, they are 2 different animals and crossbreeding them is a problem.