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Front Disc Swap Pictorial; Upgrading to disc brakes
Topic Started: Aug 24 2011, 05:36 PM (621 Views)
j54mitsu
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There are 78 images in this set, so I'm only including the most interesting. Also, I'll be posting a more detailed version on earlycj5.com with parts lists, so this is just the pictures. If you go through the set, then you'll see notes on each step (picture).

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Jack up wheel

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J54 Disc Brake Swap

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Remove cap

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Remove snap ring

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Remove spindle nuts
Ryan in Central/Northern Virginia
1976 trans-make Mitsubishi J54: Licensed CJ-3B clone, 4DR5 4cyl 2.7L Biodiesel (isolated & heated SVO fuel system), 24V, 4spd, Dana 18 twin stick clone, Dana 25 & 44 clone 5.375 R&P, Front with Lock-Right and disc brakes, Rear 11" drum brakes, Warn lockout hubs, 12V converter for accessories, US style taillights, MB/M38 HD diff cover, Swing out tailgate, K&N air filter, Bestop Tiger Top.
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j54mitsu
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Posted Image
Remove stock brakes

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Remove the spindle

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J54 owners: Dust covers require more room

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Get old studs out

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Hammer in the studs
Ryan in Central/Northern Virginia
1976 trans-make Mitsubishi J54: Licensed CJ-3B clone, 4DR5 4cyl 2.7L Biodiesel (isolated & heated SVO fuel system), 24V, 4spd, Dana 18 twin stick clone, Dana 25 & 44 clone 5.375 R&P, Front with Lock-Right and disc brakes, Rear 11" drum brakes, Warn lockout hubs, 12V converter for accessories, US style taillights, MB/M38 HD diff cover, Swing out tailgate, K&N air filter, Bestop Tiger Top.
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j54mitsu
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Posted Image
Install wheel studs

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Grinding Caliper and Knuckle

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Grind fill plug to 1 cm thickness

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Mock up

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Put felt and rubber seal on axle. Install kingpin bearings and knuckle. Check hardline
Ryan in Central/Northern Virginia
1976 trans-make Mitsubishi J54: Licensed CJ-3B clone, 4DR5 4cyl 2.7L Biodiesel (isolated & heated SVO fuel system), 24V, 4spd, Dana 18 twin stick clone, Dana 25 & 44 clone 5.375 R&P, Front with Lock-Right and disc brakes, Rear 11" drum brakes, Warn lockout hubs, 12V converter for accessories, US style taillights, MB/M38 HD diff cover, Swing out tailgate, K&N air filter, Bestop Tiger Top.
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j54mitsu
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J54 owners: install 3/8 nut onto hardline

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Tighten king pin bolts

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Set preload

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Install rubber part of seal

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Install knuckle seal
Ryan in Central/Northern Virginia
1976 trans-make Mitsubishi J54: Licensed CJ-3B clone, 4DR5 4cyl 2.7L Biodiesel (isolated & heated SVO fuel system), 24V, 4spd, Dana 18 twin stick clone, Dana 25 & 44 clone 5.375 R&P, Front with Lock-Right and disc brakes, Rear 11" drum brakes, Warn lockout hubs, 12V converter for accessories, US style taillights, MB/M38 HD diff cover, Swing out tailgate, K&N air filter, Bestop Tiger Top.
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j54mitsu
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Posted Image
Gasketing the knuckle flange

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Install spindle and caliper bracket

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Install bracket

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Fill up the knuckle with grease

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Install hub and rotor
Ryan in Central/Northern Virginia
1976 trans-make Mitsubishi J54: Licensed CJ-3B clone, 4DR5 4cyl 2.7L Biodiesel (isolated & heated SVO fuel system), 24V, 4spd, Dana 18 twin stick clone, Dana 25 & 44 clone 5.375 R&P, Front with Lock-Right and disc brakes, Rear 11" drum brakes, Warn lockout hubs, 12V converter for accessories, US style taillights, MB/M38 HD diff cover, Swing out tailgate, K&N air filter, Bestop Tiger Top.
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j54mitsu
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Posted Image
Install spindle nuts and washer

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Anti sieze slide threads

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Grease slides

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Prep caliper for installation

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Install caliper and slides
Ryan in Central/Northern Virginia
1976 trans-make Mitsubishi J54: Licensed CJ-3B clone, 4DR5 4cyl 2.7L Biodiesel (isolated & heated SVO fuel system), 24V, 4spd, Dana 18 twin stick clone, Dana 25 & 44 clone 5.375 R&P, Front with Lock-Right and disc brakes, Rear 11" drum brakes, Warn lockout hubs, 12V converter for accessories, US style taillights, MB/M38 HD diff cover, Swing out tailgate, K&N air filter, Bestop Tiger Top.
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j54mitsu
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Install soft line after you've gotten the proper loop

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Put gasketing on lock out hub bearing section

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Install lock out hub bearing section

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Install lock out hub cap

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Semi-finished product
Ryan in Central/Northern Virginia
1976 trans-make Mitsubishi J54: Licensed CJ-3B clone, 4DR5 4cyl 2.7L Biodiesel (isolated & heated SVO fuel system), 24V, 4spd, Dana 18 twin stick clone, Dana 25 & 44 clone 5.375 R&P, Front with Lock-Right and disc brakes, Rear 11" drum brakes, Warn lockout hubs, 12V converter for accessories, US style taillights, MB/M38 HD diff cover, Swing out tailgate, K&N air filter, Bestop Tiger Top.
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j54mitsu
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Posted Image
Bleed lines. Remove appropriate RPV.

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Put the tire back on.

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Finished product


I hope this helps!

For parts check out this thread: http://www.earlycj5.com/forums/showthread....ring-race-combo
Ryan in Central/Northern Virginia
1976 trans-make Mitsubishi J54: Licensed CJ-3B clone, 4DR5 4cyl 2.7L Biodiesel (isolated & heated SVO fuel system), 24V, 4spd, Dana 18 twin stick clone, Dana 25 & 44 clone 5.375 R&P, Front with Lock-Right and disc brakes, Rear 11" drum brakes, Warn lockout hubs, 12V converter for accessories, US style taillights, MB/M38 HD diff cover, Swing out tailgate, K&N air filter, Bestop Tiger Top.
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