Jeep Cherokee: Rear Disc Brake Swap - KJ/ZJ No Welding; Bolt-on Conversion ['91-'01 XJ]

1991 - 2001 Jeep Cherokee XJ. How to actually Disc Brake swap a Chrysler 8.25 Rear Axle. Here, the process shall be documented in a valiant effort to display what it's actually like, things that actually happen, and how much time and money it actually cost.

1990 - 2001 Cherokees and Comanches with a Dana 35 can use Grand Cherokee ZJ (1993 - 1998) parts instead of Jeep Liberty (2003 - 2007) parts for the same result, which will also be a bolt-on conversion with no welding required.

1984 - 1989 Cherokees and Comanches with a Dana 44 or a non-c-clip Dana 35: the process is different but overall similar. Check out Nick’s video on his 1989 XJ:    • 89 Cherokee Dana 35/44 Rear Disk Brak...  

Which Rear Axle do you have?:    • How to Identify Which Rear Axle You H...  

What is Brake Bias and why is it important?:    • Why are Front Brakes Larger than Rear...  
Why bigger brakes won’t actually stop your car faster:    • Why Big Brakes Won't Stop You Faster ...  

Thanks to Bryant for his knowledge and assistance on this project:    / @xj_overlander  

YOU WILL REQUIRE:
-03-07 KJ Backing Plates
-03-07 KJ Backing Plate to Axle mounting studs
-03-07 KJ Parking Brake shoes and hardware (new)
-03-07 KJ Rear Brake Rotors & Pads (new)
-03-07 KJ Rear Calipers & Banjo bolts (new)

-99-04 WJ Rear Rubber brake lines
-84-01 XJ Dana 30 wheel studs (x10)
-93-98 ZJ Proportioning Valve Spring
-97-01 Disc Brake compatible Parking Brake Cables
-84-01 Pre-Flared Brake Lines 12” & 40”

-97-01 XJ Front Parking Brake Cable & Equalizer
-91-04 XJ Rear Axle Wheel Bearing TIMKEN 6408
-91-04 XJ Rear Axle Wheel Seal TIMKEN 8835S
-97-07 XJ Differential Center pin bolt
-91-07 XJ Differential Cover Gasket
-Differential Fluid
-Wheel Bearing Puller 57129 (Autozone)

This project cost me a grand total of $568.17 for everything. However, on a budget, I could have done it for $304.93. Either way, a lot cheaper than the $857.53 for a “kit”, and a lot more expensive than about $150 to completely overhaul the existing drum brakes.

TO THE JUNKYARD:
-Sockets 10mm to 15mm
-14mm Deep Socket
-8mm Ratchet Wrench
-Needle-nose pliers
-Hammer
-Prybar/ Large Screwdriver
-Something to cut parking brake cables with, because you ain’t getting them off.
-A Crescent Wrench, because the Proportioning valve caps seem to vary in size from 13/16” to 3/4”
-Jack/ stands
-A drain pan (?)

PART LINKS
-KJ Rear Rotors: https://www.rockauto.com/en/catalog/j...

-KJ Rear Brake Pads: https://www.rockauto.com/en/catalog/j...

-KJ Rear Calipers: https://www.rockauto.com/en/catalog/j...

-Powerstop Caliper Compatible Banjo Bolts: https://rb.gy/gn94k

-KJ Parking Brake Shoes: https://www.rockauto.com/en/catalog/j...

-KJ Parking Brake Hardware Kit: https://www.rockauto.com/en/catalog/j...

-Parking Brake Equalizer: https://www.amazon.com/dp/B07GNKMNGP?...

-97-01 XJ Rear Disc Swap Parking Brake Cables: https://www.quadratec.com/p/crown-aut...

-Front Parking Brake Cable:
https://www.rockauto.com/en/catalog/j...

-Rear Axle Wheel Bearings: https://www.rockauto.com/en/catalog/j...

-Rear Axle Seals: https://www.rockauto.com/en/catalog/j...

-Dana 30 Lug Studs: https://www.rockauto.com/en/moreinfo....

-WJ Rear Left Brake Hose: https://www.rockauto.com/en/moreinfo....

-WJ Rear Right Brake Hose: https://www.rockauto.com/en/moreinfo....

-Chrysler 8.25 Center Pin Bolt: https://rb.gy/v5888

Keep the drums instead: https://www.rockauto.com/en/moreinfo....

Can’t Stop:    • Punch Deck - I Can't Stop  
Offworld:    • HurricaneTurtle – Offworld [Synthwave...  
Dominant:    • Punch Deck - Dominant  

00:00 The Intro
00:04 The Premise
03:50 Phase 1: Find the Parts
07:15 Phase 2: Operation Begins
07:55 Differential Teardown
09:17 Lug Nut Studs
10:31 Remove Brake Lines
11:05 Remove Drum Brake
12:07 Backing Plate Studs
13:11 Wheel Bearing
16:16 Backing Plate Install
17:07 Parking Brake Shoes & Hardware
21:39 Axle Shaft Install
24:21 Differential Assembly
29:16 Brake Rotor & Parking Brake Adjust
30:37 Brake Caliper
32:42 Custom Brake Lines
34:36 Differential Cover and Fluid
35:29 Proportioning Valve
36:50 The Master Cylinder
39:36 Parking Brake Cables
45:06 Routing Rundown
47:04 Initial Test
50:04 Final Thoughts