Front Disc Brake Conversion '73 J4000 Dana 44 Closed Knuckle

[Kowpie]

This is a companion post documenting the conversion from drum to disc brakes during my restoration. The previous post covered the rear, this will be the front. As stated before, I have made every attempt to keep the vehicle in original condition but with a few modern options such as more efficient disc brakes. While restoring and modernizing this axle, the ball wiper seals, trunnion bearings, and locking hubs were replaced. Most parts were easily sourced except components for the early hubs. The hubs were in terrible condition from years of neglect and improper maintenance, so they were replaced as complete units.
The parts:
1) Front Disc Conversion Kit, #BDBK44 63-73 Dana 44 Axles, purchased from TheJeepesterMan.Com, $729.00
thejeepsterman.com/products/6915-jeep-wagoneer-and-j-truck-disc-brake-conversion-kit-dana-44-1963-1973/
My experiences: The kit was complete with all grade 8 hardware and brake hoses (you can select your length). The rotors are large at 12 1/4" and vented at 1 1/8" thick. Some of the components (calipers, brake hoses) were drop shipped from speedway.com and appear to be imported. The balance of the kit parts appear to be locally sourced. I noticed that some of these kits provide a new hub, this one does not... you use you own. New longer wheel studs are included. I have aftermarket 15" steel wheels and there was interference. I shaved a small amount from the caliper surface and used a 0.25" wheel spacer to alleviate the rubbing. Communication with Jeepster Man was strictly web based. I tried to call and was told. "I am not near the office to help so it is best you order everything online yourself". All communication was via email and at times was a little slow (2-3 days to answer questions).
My summation: The kit was good even with some parts outsourced. Customer service was decent to sub-standard.

2) Closed Knuckle Ball Axle Bearing, Shim, Seal and Wiper Kit, #24-6259, purchased from BJ's Off-Road, $135.00
bjsoffroad.com/Closed-Knuckle-Ball-Rebuild-Kit_p_48.html
The kit is complete with good quality components. Timken bearings and races were supplied and the wipers and seals were visually and physically top-shelf pieces. Plenty of shims were supplied. Shipping was quick and the price reasonable. BJ's is a great place to deal with and get your stuff!

3) Locking Hubs, #29062, purchased from Summit Racing, $236.99
summitracing.com/parts/WRN-29062
Warn hubs are not what they used to be. The hubs themselves were of decent quality but the included hardware was sub-standard. The outer gaskets were not protected in the box and had been mangled in shipping from the manufacturer. I had to make my own from quality gasket material that I keep on hand for just these occasions. It is unfortunate that a once proud American brand is now relegated to "well, it is all you can get so I better be happy with it" part. As for Summit, they are amazing. Always my go-to for parts. Great selection, good pricing, fast shipping, and never a problem on returns.

Regards
Gary

[Kowpie]

More pictures

[Kowpie]

Again...

[Kowpie]

Old locking hub

[Harry Dawg]

Looking good!

I did a similar swap on my closed knuckle front end. Your calipers and rotors are definitely larger than mine. That will be nice, especially if you're going to add a brake booster.

I used a Berkeley fishing scale to set preload when doing the king pin bearings. Set them to 18 LBS because I'm running oversize tires.

I attached a pic of the TSM just in case you find it useful. Might already have this info.

Glad to see someone else preserving a cool piece of solid axle history.

Sent from my Pixel 4a (5G) using Tapatalk

[Kowpie]

Thanks!
The rotors are definitely large. I was surprised at the size when I received them. I am using the original vacuum booster that I had restored from a builder in Lynnwood, Washington (Power Brake Booster Exchange). They did a great job with the rebuild. I have a vintage brass pull scale that I have been using for 40ish years that I used for the bearing preload. I have calibrated it a few times over the years and I can say that the folks knew how to make tools way back in the day. I went with the high end of the scale at 16 lbs. Thanks for the screen shot but an original, greasy, well-used TSM was one of the first things I purchased when I acquired this truck ($80.00 on evilbay!). Nice to hear another appreciates and uses the original vintage hardware. I don't know why but those old axles and the spring setups just make me smile. Take care Harry and thanks for the comments.

Gary

[tgreese]

Re your review, I've always been happy with Summit. Lowest price around, service, selection - recommended. Too bad about the hubs. I'd think you could find some good used ones. You could run the old ones locked for the time being - you don't really need locking hubs. In '73, your truck would have come with drive flanges. Warn hubs were not on the factory option list until 1974. Aftermarket only, dealer installed "Jeep Authorized" accessory in 1973.