Our shop is in the middle of what has to be the baddest 96 project going. It will not be complete unless we can resolve the brake dilema. Does anyone have an idea on how to get dual + piston calipers on this 4X4 392 fully blown, air locked, sky rider?
96 Big Brake Upgrade
- Thread starter jri4au1
- Start date
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yo jri4au1,
WELCOME!
Please provide the plan for the project such as the probable SAS swap, wheel/tire upsizing, etc.
Take a look at my broncolinks.com's Caliper scetion for some caliper option LINKs @ http://www.broncolinks.com/index.php?index=246
some for example are;
1 ton Rotor Installation on Dana 44 SAS; "...I used 1990 F250 caliper mounts and calipers..." (pics are gone)
Chris wrote; "...
The rotor is the key. The stock D44 rotor has a diameter that is too small, the stock 8 lug D60 rotor hole is way to big to think about fitting properly to try and convert it to 5 on 5 1/2. I found the 2002 Dodge Ram 1500 rotor 5 on 5 1/2 to work after being machined down to 12.6" diameter. Compare rotor sizes below:
You get a little bit bigger diameter rotor over the D44 for more leverage and better stopping power. The biggest increase in braking comes from the larger, twin piston calipers and larger pads. There is more surface contact between the pad and rotor.
I did not need a larger than stock master cylinder with these twin piston calipers and rear drum brakes. I did need to go with a 1 3/8" F350 master and got the matching booster when I swapped-in a Sterling rear with disk brakes. I don't know if this will work on the TTB.
My Cost:
Ultra premium Napa rotors $130
Machining $120
Used caliper mounts and Calipers maybe $100
Rebuilt calipers $112
Premium Pads $60
There a less expensive parts and you might do a little better at a machine shop than I did.
Ford Dana 44 rotor:
Diameter:11.72"
Height:2.54"
Thickness When New:1.03"
Discard Thickness:.96"
Ford D60 Rotor
Diameter:12.56"
Height:3.23"
Thickness When New:1.25"
Discard Thickness:1.18"
2002 Dodge Ram 1500 Rotor
Diameter : 13.23"
Height : 2.66"
Thickness New : 1.1"
..."
============
Also check out the Hydro Boost, F350 Master Cylinder & Booster Installation Section @ http://www.broncolinks.com/index.php?index=253
GL!
WELCOME!
Please provide the plan for the project such as the probable SAS swap, wheel/tire upsizing, etc.
Take a look at my broncolinks.com's Caliper scetion for some caliper option LINKs @ http://www.broncolinks.com/index.php?index=246
some for example are;
1 ton Rotor Installation on Dana 44 SAS; "...I used 1990 F250 caliper mounts and calipers..." (pics are gone)
Chris wrote; "...
The rotor is the key. The stock D44 rotor has a diameter that is too small, the stock 8 lug D60 rotor hole is way to big to think about fitting properly to try and convert it to 5 on 5 1/2. I found the 2002 Dodge Ram 1500 rotor 5 on 5 1/2 to work after being machined down to 12.6" diameter. Compare rotor sizes below:
You get a little bit bigger diameter rotor over the D44 for more leverage and better stopping power. The biggest increase in braking comes from the larger, twin piston calipers and larger pads. There is more surface contact between the pad and rotor.
I did not need a larger than stock master cylinder with these twin piston calipers and rear drum brakes. I did need to go with a 1 3/8" F350 master and got the matching booster when I swapped-in a Sterling rear with disk brakes. I don't know if this will work on the TTB.
My Cost:
Ultra premium Napa rotors $130
Machining $120
Used caliper mounts and Calipers maybe $100
Rebuilt calipers $112
Premium Pads $60
There a less expensive parts and you might do a little better at a machine shop than I did.
Ford Dana 44 rotor:
Diameter:11.72"
Height:2.54"
Thickness When New:1.03"
Discard Thickness:.96"
Ford D60 Rotor
Diameter:12.56"
Height:3.23"
Thickness When New:1.25"
Discard Thickness:1.18"
2002 Dodge Ram 1500 Rotor
Diameter : 13.23"
Height : 2.66"
Thickness New : 1.1"
..."
============
Also check out the Hydro Boost, F350 Master Cylinder & Booster Installation Section @ http://www.broncolinks.com/index.php?index=253
GL!
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