89 Cherokee Dana 35/44 Rear Disk Brake Conversion
1989 Jeep Cherokee XJ Pioneer Renix 4.6L I6 AW4 NP231 6" RE Lift 35"x12.5" KM2s
This swap covers how to convert an XJ Non C-Clip Dana 35 to ZJ Rear Disk Brakes. The same should apply for a Dana 44. Regular Dana 35's should be a direct swap with little to no modification.
Parts needed from a 1994 - 1998 ZJ Grand Cherokee with Dana 35 Disk Brakes:
Caliper Backing Plate and Dust Shield
Rear Calipers
Rear Caliper Banjo Bolt
Rear Brake Hose
Rear Brake Pads
Rear Brake Rotors
Parking Brake Shoes
Parking Brake Hardware Kit
Parking Brake Lever Arm
Note: A ZJ Parking Brake Cable (41") was too short for my Jeep and didn't have the slack needed to mount properly.
TeraFlex # 4304171 Parking Brake Cable (66") Should fit 87-96 XJ's properly (It's tight but it'll work)
TeraFlex # 4304169 LH Parking Brake Cable (42") Should fit 97-01 XJ's properly (Un-tested)
TeraFlex # 4304175 RH Parking Brake Cable (66-1/8") Should fit 97-01 XJ's properly (Un-tested)
Parking Brake Cable Lengths, Slack measured from Body Mount to Bracket:
87-89 XJ's: 54" for both, ~10" of Slack, Cylinder Ends
90-92 XJ's: 53" for both, ~10" of Slack, Cylinder Ends
93-96 XJ's: 52" for both, ~10" of Slack, Ball End/Cylinder End
97-01 XJ's: 36" Left, 72" Right, No Slack, Cylinder Ends
For Dana 44 and Dana 35 Non C-Clips:
Axle Bearing Retainer from a Disk Brake Equipped Dana 44 Axle #5083678AA
~ Caliper Backing Plate and Retainer Plate have to be re-drilled to fit older axles
~ Inner Rotor Hub may need to be grinded down to fully seat on axle shaft
~ Longer Wheel Studs may be necessary