So this is a pretty common mod for XJers and on NAXJA, figured i'd post it up here.
Went to the LKQ jy in Greenville, and snagged the backing plates, dust shields, backing plate studs and nuts, the calipers, and the flexible hoses. I also grabbed the ZJ e-brake cables, though I ended up not needing them. I also got the wheel studs from the front of an XJ.
The backing plate for the discs is quite a bit thicker than for the drums on the 8.25", so that is why you need the backing plate studs, they are longer for better thread engagement, and the XJ front wheel studs (or any studs from a ZJ) - because the rotor is thicker than the drum.
The setup from a D35 can work, but you need to enlarge the center hole a tad for the 8.25. If you happen to find a libby (which I didnt), it is a direct swap.
The ebrake cables can cause problems. KJ cables are too long, but can be looped and work fine, they have the same ends as the ZJ. The Driver cable from a ZJ works, but the pass side is too short. XJ cables are obviously perfect length, but have different ends. Someone on naxja came up with a nice fix for that which I will show later.
For the brakelines - the ZJ calipers have a separate, short flex hose. The later KJ lines have the flex hose permanently mounted to the hardline, so they won't work. I just used the ZJ lines and bent my XJ hardlines to mate up with them, and they bolted together perfectly.
I didn't take the rotors because they were in terrible shape - got new rotors and pads from Rockauto.com. I also returned the calipers for cores - piece of mind.
Pictures to come tonight when I get back in the garage. I am a little over half way through. One side is complete, just need to finish the other, replace gear oil, and bleed.
Stay tuned.
Went to the LKQ jy in Greenville, and snagged the backing plates, dust shields, backing plate studs and nuts, the calipers, and the flexible hoses. I also grabbed the ZJ e-brake cables, though I ended up not needing them. I also got the wheel studs from the front of an XJ.
The backing plate for the discs is quite a bit thicker than for the drums on the 8.25", so that is why you need the backing plate studs, they are longer for better thread engagement, and the XJ front wheel studs (or any studs from a ZJ) - because the rotor is thicker than the drum.
The setup from a D35 can work, but you need to enlarge the center hole a tad for the 8.25. If you happen to find a libby (which I didnt), it is a direct swap.
The ebrake cables can cause problems. KJ cables are too long, but can be looped and work fine, they have the same ends as the ZJ. The Driver cable from a ZJ works, but the pass side is too short. XJ cables are obviously perfect length, but have different ends. Someone on naxja came up with a nice fix for that which I will show later.
For the brakelines - the ZJ calipers have a separate, short flex hose. The later KJ lines have the flex hose permanently mounted to the hardline, so they won't work. I just used the ZJ lines and bent my XJ hardlines to mate up with them, and they bolted together perfectly.
I didn't take the rotors because they were in terrible shape - got new rotors and pads from Rockauto.com. I also returned the calipers for cores - piece of mind.
Pictures to come tonight when I get back in the garage. I am a little over half way through. One side is complete, just need to finish the other, replace gear oil, and bleed.
Stay tuned.