Rear ZJ disc brakes to Cherokee XJ Chrysler 8.25

Old 08-31-2010, 08:50 PM
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DmC
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Year: 1998 XJ
Model: Cherokee
Default Rear ZJ disc brakes to Cherokee XJ Chrysler 8.25

Vehicle: 1998 Jeep Cherokee Sport
Axle: Chrysler 8.25

I hate drum brakes and found there are a few different ways to change the rear brakes to disc brakes on the XJ. I found you can swap any rear discs from a 1994-1998 GRAND Cherokee with little modification.

Parts needed:
94-98 GRAND Cherokee Rear Disc Brakes and proportioning valve
Diff Fluid
Brake Fluid
RTV Sealant
Dremel with grinding stone



Step 1:Acquire all the parts needed from a Grand Cherokee, years 1994-1998. Calipers, Backing Plate, Soft lines, all the hardware.


Step 2: Jack up your Cherokee and put it on jack stands.


Step 3:Remove Differential cover to drain the fluid. Be sure to remove only the lower bolts first to drain the fluid easier and so it doesn’t get every where. (13MM)

Step 4: Remove pinion shaft bolt (8MM). Once this is done you can push both of the axles in, causing the C-clips to fall off the axles. Then pull both axles out.


Step 5: Remove all the drum hardware from the axle. Leaving only the 4 studs for the backing plate.


Step 6: Now you will need to take the ZJ backing plate and grind down the center to fit the axle. I used my dremel with a grinding stone and it worked just fine.


-I went ahead and change the 4 studs as they were a little rusty and old. I used grade 8 3-8/16 x 1 ˝ bolts with lock washers and new nuts. Just use a hammer to pound out the old studs. I would recommend this just to make the install a little easier.

-I also went ahead and change the axle seals. Use a flat head or pry bar and pull the old seal out. And I used a rubber mallet to put the new seal in. Be sure to hit the seal in a circle so it goes in evenly.


Step 7:Install ZJ backing plate


Step 8: Install parking brake assembly. Retaining clips then bottom spring/ adjuster then E-brake cable pivot then top spring


Step 9:Install axles. Install c-clips and pinion shaft bolt. Be sure to clean the differential with brake cleaner before reinstalling.


Step 10:Install Rotors


Step 11: Install Calipers. You will have to reroute the brake hard line to fit with the soft line.


Step 12: Install brake cables. I went ahead and bought new cables from Napa. Part numbers: 95969 and 95963. You can either use the stock cables form the XJ or ZJ but modifications will be needed. I didn't get any pictures of this.

Step 13: Install Proportioning valve
Here are two excellent write ups as on how to change out the Proportioning valve. You can either change the whole unit or just the internals.
http://go.jeep-xj.info/HowtoZJvalve.htm
http://go.jeep-xj.info/HowtoPvalve.htm

Step 14: Install differential cover. Now is the time to paint it if you like.


Step 15: Bleed brakes/ adjust brake cable.

Finished product


Over all it is not a hard modification/install. Basic tools were needed. I would recommend. Less body roll when breaking and no more clunks after releasing the brakes from a stop.
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Old 06-04-2016, 08:40 AM
  #2  
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A kit with all parts needed at a reasonable price is available from Big David in the following link.

https://www.cherokeeforum.com/f71/di...on-kit-159484/
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