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 bolton conversion with no welding required.

1984 1989 Cherokees and Comanches with a Dana 44 or a noncclip 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:
0307 KJ Backing Plates
0307 KJ Backing Plate to Axle mounting studs
0307 KJ Parking Brake shoes and hardware (new)
0307 KJ Rear Brake Rotors & Pads (new)
0307 KJ Rear Calipers & Banjo bolts (new)

9904 WJ Rear Rubber brake lines
8401 XJ Dana 30 wheel studs (x10)
9398 ZJ Proportioning Valve Spring
9701 Disc Brake compatible Parking Brake Cables
8401 PreFlared Brake Lines 12” & 40”

9701 XJ Front Parking Brake Cable & Equalizer
9104 XJ Rear Axle Wheel Bearing TIMKEN 6408
9104 XJ Rear Axle Wheel Seal TIMKEN 8835S
9707 XJ Differential Center pin bolt
9107 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
Needlenose 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?...

9701 XJ Rear Disc Swap Parking Brake Cables: https://www.quadratec.com/p/crownaut...

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