Disc Brake Conversion for Dana 44

[74 Bronco Billy]

Hi Guys,

Need a little help figuring out what to do next. I bought some parts at the Wild Horses swap meet in Oct., and now I'm concerned they may not all fit together. SO, here's what I have:

Dana 44 Front Axle from my 1974 Bronco
Pair of Rt and Lt of '76/'77 Bronco Knuckles, 5 lug, Rt. C 37917, Lt. C 37918
Pair of Front Disc Brake Brackets, '78 F-150/ Lg Bronco, 5 lug, Bendix 3204148R, 3204157 L
Pair of Spindles, appear to be from '76 Bronco, 5 lug
Pair of Rotors, dual, center finned, 5 lug, no numbers, look brand new but surface rust.

I'm completely rebuilding the axle, so, for this part, I'm going from the axle housing out. The 5 lug Brackets, Spindles and Knuckles fit together. Now the questions:
1. DO I order Calipers for a '76/'77 Bronco, or the /78 F 150? Are they the same? Do I order hubs for a '76/'77 Bronco or the '78? Ugh!
2. Can I get the '76 dust shields to fit this? Or do I go in search of a '78 F 150 for parts?
3. I need a diagram of the '76/'77 disc brakes...I can't figure out how the caliper bracket goes on, and how the caliper fits on it. Is it knuckle, spindle, caliper, or K-C-S? I've looked for diagrams and can not find one that is particular to the Bronco for '76/'77.
4. One of the spindles has a deeper inner groove than the other. Could it be from the seal rubbing it? Or are they two different models, requiring different seals?

Thanks to anyone that can help.

 

[tinytim02]

1. You should look into using the bigger t-bird calipers. BC Broncos sells a complete kit http://store.bcbroncos.com/products/t-bird-caliper-kit-for-early-bronco or they can be sources locally.

 

[Jdgephar]

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[74 Bronco Billy]

Tiny Tim, thanks for the link for the T Birds calipers, I will look at that kit.

 

[74 Bronco Billy]

jdgephar,

Can you give me another few pictures at different angles, one from straight on and a few with calipers in pace or dust shields?

 

[broncnaz]

1. 76/77 bronco and 76-79 bronco/F150 calipers are all the same so are the hubs so its up to you what year you want to use.
2. Same goes for the dust shields. a lot of people leave them off. up to you.
3. knuckle, caliper bracket, spindle,
4. seals are all the same. A new seal should still work but if your concerned then a new spindle may be in order. but they are spendy. Just don't throw that one away it can be a good spare if you decide not to use.

 

[74 Bronco Billy]

Thank you! I was perplexed, and everyone here just rocks. Now I can research it and get on with the build. Any other advice for rebuilding these brakes or the Dana 44 axle is most appreciated.

 

[Jdgephar]

jdgephar,

Can you give me another few pictures at different angles, one from straight on and a few with calipers in pace or dust shields?

I don't have the dust shields. Here's a few more pics.

 

[Apogee]

I pulled my dust shields when I redid my brakes as I was getting mud and rocks wedged between them and the rotor. The rotor scoring was one thing, but the grinding/squeaking was too annoying to ignore.

 

[NC-Fordguy]

Tiny Tim, thanks for the link for the T Birds calipers, I will look at that kit.

The t-bird banjo bolts and flexible brake line are difficult to source locally. Most parts houses don't stock them and their data base doesn't show them to be available. The caliper is no problem.

As previously stated BC broncos has all the stuff you may need.

 

[74 Bronco Billy]

Anyone have pictures of the T-Bird Calipers on the Rotor brackets?
Is the only difference the size of the piston for more braking power?
Thanks for the previous pictures, they helped a lot.

 

[NC-Fordguy]

Anyone have pictures of the T-Bird Calipers on the Rotor brackets?
Is the only difference the size of the piston for more braking power?
Thanks for the previous pictures, they helped a lot.

It looks and fits the same. Both calipers use the same pads. The difference is the piston on the t-bird caliper is larger, the banjo bolt is larger thus requiring the hose end to be larger.

 

[sykanr0ng]

The t-bird banjo bolts and flexible brake line are difficult to source locally. Most parts houses don't stock them and their data base doesn't show them to be available. The caliper is no problem.

As previously stated BC broncos has all the stuff you may need.

For other sources:

http://classicbroncos.com/forums/showthread.php?t=269393

 

[Jdgephar]

Anyone have pictures of the T-Bird Calipers on the Rotor brackets?

Is the only difference the size of the piston for more braking power?

Thanks for the previous pictures, they helped a lot.

FYI, mine are the T-bird calipers from BC Broncos.


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[74 Bronco Billy]

Clean the rust from Dana 44

I'm back, got all the parts to rebuild and convert the brakes and the Dana 44. I've cleaned and powder coated the differential, but I still have some rust on the hub seals and the carrier race beds. I've been told to use 400 grit sand paper, then go up. How about brass wheel, small, like for a dremel? Any other ideas?

 

[NGABronco]

Be aware that with the 76' knuckles, your wheels need 3.5" or less of backspacing!! Just FYI!!! Looking good!!!;D;D;D

 

[DirtDonk]

And with the powder coating, make sure none is in the tapered holes of the ball joints. Less critical might be the tie-rod end holes in the knuckles, but I would still clean them out with a reamer or other careful method.

With the C-bushing pads coated also, expect your C-bushings to squish out even more than they normally might. Make sure to use a good amount of lubricant, such as liquid had soap.

Lookin' good even with the rust!

Paul

 

[5001craig]

I put my dust shields on. Didn't really know that some were leaving them off.

Only advice I have is to put the Rotor on first then the spindle. I thought the rotor went outside the spindle and got good at installing/removing everything. Also, make sure your bleeders are up. Ask me how I know this. In this picture you can see the bleeder up. I have one pointing down too but that is not the way to do it.

 

[Jdgephar]

Just so there is no confusion, that is the GM disk brakes in 5001craigs photos


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[DirtDonk]

Yep, Ford brakes do install with the caliper mounting bracket first, then the spindle. GM based kits do the spindle first, like Craig said.

Removing the dust shields is a long-held tradition with off-roaders for the reasons stated.
I've always left mine on because they do still have a purpose, they make the install look more complete, and I've personally yet to get a rock lodged therein!
I've certainly seen some real boulders lodged in some pretty strange places, so it's certainly not without precedent. Kind of leaves it up to the end user then.

For a street rig it's pretty much a non-issue.

Paul