Author Topic: Big Brake Mod (IFS Mod & Rear Disc)  (Read 14978 times)

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golana

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Big Brake Mod (IFS Mod & Rear Disc)
« on: Mar 16, 2011, 01:47:55 AM »
This Thread is Featured in our Tech from our Forum Members section!



Well, i have a 1985 toyota 4x4. i had the stock brake system, and it wasnt bad, but it wasnt anything special, thats for sure!

i did some research, and came up with everything i needed for the swap!

tools and stuff needed:
1/2" fine thread tap
1/2" drill bit
angle grinder (or lathe if you have access to one)
drill
4x 1/2" fine thread, gr.8 1.25" long bolts

first off, for the front, i used:
1998 Toyota Tacoma rotors
1994 Toyota Pickup v6 calipers
1986 Toyota Pickup hubs



some slight modification had to be done to both the calipers and the steering knuckle. both are no big deal!
you do have to modify the IFS hubs though... if you dont have access to a lathe, you can use an angle grinder, just be careful not to take off too much material...

IFS Hubs


had to throw the hubs on my lathe to turn down the little ear things...


i had to take down a bit more than this, but you get the idea


use the 1/2" fine thread tap on the mounting ears of the caliper.
then use the 1/2" drill bit on the mounting ears of the solid axle knuckles. you just need to hog out enough material to fit a fine thread 1/2" bolt.


now the 98 tacoma rotors fit overtop of the hubs!


1/2" tap


tapped the 94 V6 calipers (i think these ones are 86 calipers though... notice the 2 sizes of pistons... the smaller ones are closest to the camera, the larger pistons are under the brake line fitting)


the calipers now mount on the outside of the ears, instead of the inside, but its no less strong... now all i have to do to change rotors is remove the wheel, and unbolt the caliper!



for the rear, i used: (you will have all this stuff laying around after the front is done)
1985 Toyota Pickup solid axle rotors
1985 Toyota Pickup solid axle calipers
1985 Toyota Pickup solid axle lug studs




i pounded out the old studs off the axle shaft and had to grind down a hair off the axle on the inside where the rotor has to sit...


once the rotor sat flush, i just installed the longer solid axle studs and bob's your uncle!


pretty good stuff! i had to make a set of wheel spacers (only 1/4" though) so i could bolt the wheel on... the shoulder of the longer studs is a hair too far out...


i saw what i needed to do, so i drew up some brackets on some 1/4" steel (i think it was 1/4"... either that or 5/16")


ohhh yea!


i cleaned the pieces up a bit, then marked where i needed to, and drilled holes


i didnt like how much space was left...


tapped the 85 solid axle calipers to 1/2" thread


i ended up cutting out another set, slightly smaller, and welding them to the plates. super beef!


love it!


no more gaps, and no chance of ever bending it haha



Braking:
after doing this swap, the brake pedal became SUPER stiff! it was really hard to push the pedal, but i could still stop. The solution to this, is a Tacoma brake booster! i also used a Tacoma brake master cylinder






i am not running a proportioning valve, and the rear does lock up before the front, so its a little sketchy driving on ice or super slippery surfaces, but the increased braking power is just unbelievable! on the trail, its just perfect! for street use, i recommend a prop. valve! i was pulling a 2300lb, 6x12' dual axle uhaul trailer loaded with my in-laws stuff when i helped them move, and had absolutely no problem stopping it!


i hope this writeup helps anyone out who is interested in doing this swap too! happy wheelin!
« Last Edit: Jun 18, 2014, 04:40:30 PM by BigMike »
-Steve

1994 4Runner - BUILD THREAD
5VZ-FE - 12" Lift - High Steer - Hydraulic Assist - IFS Mod - Scuba Mod - Ford Fuel Tank - E-Fan - Doubler = 96.31:1 Crawl Ratio

Brake setup
FRONT: 98 Tacoma Rotors/Brake Master Cylinder/Booster, 94 V6 Pickup Calipers, 86 IFS Hubs
REAR: 85 Solid axle Rotors/Calipers/Lug Studs, 1/4" Wheel Spacer

Peterbuilt84

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #1 on: Mar 16, 2011, 02:13:09 AM »
Thanks for the writeup  :biggthumpup:

Do you think the braking could of been helped with just a new master cylinder, or was the booster needed also?

golana [OP]

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #2 on: Mar 16, 2011, 03:02:27 AM »
Thanks for the writeup  :biggthumpup:

Do you think the braking could of been helped with just a new master cylinder, or was the booster needed also?

the stock booster didnt have enough vacuum to help push the pedal down. the only reason i swapped master cylinders is mine seized and wasnt releasing the fronts... any time i stepped on the brakes, the fronts got tighter and tighter, till i couldnt drive, even in 4lo-lo...

the booster is a must.
-Steve

1994 4Runner - BUILD THREAD
5VZ-FE - 12" Lift - High Steer - Hydraulic Assist - IFS Mod - Scuba Mod - Ford Fuel Tank - E-Fan - Doubler = 96.31:1 Crawl Ratio

Brake setup
FRONT: 98 Tacoma Rotors/Brake Master Cylinder/Booster, 94 V6 Pickup Calipers, 86 IFS Hubs
REAR: 85 Solid axle Rotors/Calipers/Lug Studs, 1/4" Wheel Spacer

SloCrawler

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #3 on: Mar 16, 2011, 08:21:42 AM »
nice right up, that widend your front correct?

golana [OP]

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #4 on: Mar 16, 2011, 11:57:42 AM »
nice right up, that widend your front correct?

correct. using the IFS hubs vs the SA hubs widens your wheel mounting surface by 3"
-Steve

1994 4Runner - BUILD THREAD
5VZ-FE - 12" Lift - High Steer - Hydraulic Assist - IFS Mod - Scuba Mod - Ford Fuel Tank - E-Fan - Doubler = 96.31:1 Crawl Ratio

Brake setup
FRONT: 98 Tacoma Rotors/Brake Master Cylinder/Booster, 94 V6 Pickup Calipers, 86 IFS Hubs
REAR: 85 Solid axle Rotors/Calipers/Lug Studs, 1/4" Wheel Spacer

SloCrawler

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #5 on: Mar 16, 2011, 01:16:07 PM »
you think this all works the same for pre 85 front axles and ifs rear axles?

Peterbuilt84

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #6 on: Mar 16, 2011, 01:22:34 PM »
the stock booster didnt have enough vacuum to help push the pedal down. the only reason i swapped master cylinders is mine seized and wasnt releasing the fronts... any time i stepped on the brakes, the fronts got tighter and tighter, till i couldnt drive, even in 4lo-lo...

the booster is a must.

I have an fj80 master cylinder that I picked up as an upgrade so I was going to put that in. Then may be a v6 booster :dunno:

golana [OP]

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #7 on: Mar 16, 2011, 04:23:20 PM »
you think this all works the same for pre 85 front axles and ifs rear axles?

pre-85 should be the same, the part #'s for the bearings and stuff is all the same, so i dont see why it would be any different :) the only difference between the year axles (iirc) is the bottom gusset. the pre-82 has no gusset, the 83/84 has the half gusset (to the leaf perch) and the 85 has the full length gusset.

and i used a IFS rear axle for the rear disc, and as far as i know, they are all the same, until you get into the 4linked rear ends and tacoma rear ends, then i dont know.
-Steve

1994 4Runner - BUILD THREAD
5VZ-FE - 12" Lift - High Steer - Hydraulic Assist - IFS Mod - Scuba Mod - Ford Fuel Tank - E-Fan - Doubler = 96.31:1 Crawl Ratio

Brake setup
FRONT: 98 Tacoma Rotors/Brake Master Cylinder/Booster, 94 V6 Pickup Calipers, 86 IFS Hubs
REAR: 85 Solid axle Rotors/Calipers/Lug Studs, 1/4" Wheel Spacer

golana [OP]

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #8 on: Mar 16, 2011, 04:26:38 PM »
I have an fj80 master cylinder that I picked up as an upgrade so I was going to put that in. Then may be a v6 booster :dunno:

i think the fj80 has the 1" bore cylinder, correct? that would work perfect. i used a tacoma because a) availability/cost, b) 1" bore. you will notice it alot harder to push the brake pedal though, unless you already have the dual diaphragm brake booster... i think -some- sr5 4runners came with the dual diaphragm boosters... there is a very noticable difference between the boosters. the single dia is only about 3" or so deep, and the dual dia is about 4, and is a bit bigger in diameter. ill go find my single and take a comparison picture for you guys.

but anyways haha, you will need a booster for the bigger master cylinder. you can use your stock one, but it will be harder to press on the pedal.
-Steve

1994 4Runner - BUILD THREAD
5VZ-FE - 12" Lift - High Steer - Hydraulic Assist - IFS Mod - Scuba Mod - Ford Fuel Tank - E-Fan - Doubler = 96.31:1 Crawl Ratio

Brake setup
FRONT: 98 Tacoma Rotors/Brake Master Cylinder/Booster, 94 V6 Pickup Calipers, 86 IFS Hubs
REAR: 85 Solid axle Rotors/Calipers/Lug Studs, 1/4" Wheel Spacer

Peterbuilt84

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #9 on: Mar 16, 2011, 05:31:42 PM »
I'm pretty sure the fj80 master does have a 1 inch bore. I guess I'll just have to keep an eye out for a booster now too to go along with the calipers and rotors.

fatkidskickrocks4x4

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #10 on: Jan 09, 2012, 01:41:57 AM »
Great write up! I might actually atttempt this!
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Michael Wollinsky

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #11 on: Jan 09, 2012, 05:32:48 AM »
i did this i put mine on an old spindle and grinded it wit a grinder while my buddy spun it be sure to wear goggles i did and still got metal in my eye
Hand built and driving daily

BadnewsBob

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #12 on: Jan 09, 2012, 06:04:34 AM »
The FJ80 master cyl has the correct valve in it for rear disc also.
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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #13 on: Feb 07, 2014, 01:38:07 AM »
Got the fronts done!! Now onto the rears!! Great write up sir!!

Nation

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #14 on: Feb 07, 2014, 06:45:23 AM »
Very nice  :usa:
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tgmaul88

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #15 on: Feb 07, 2014, 09:49:51 AM »
this is how i set my brakes up in the front, all good!

helipilot77

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #16 on: Feb 08, 2014, 01:50:57 PM »
I have the FJ-80 master cylinder in my 87' 4runner. So that is why my pedal is stiffer. Thank you for solving my problem. :turtle3:
-1987 SR5 4runner, 1KZ-te turbo diesel with custom 3" S.S. dump pipe, R-151f transmission, marlin dual ultimate transfer cases w/ triple shifter, SAS, 35's
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-My front axle service write-up http://board.marlincrawler.com/index.php?topic=97311.0[/ur

lucky7

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #17 on: Feb 08, 2014, 05:08:41 PM »
Doesn't this widen the front by 3"s too?

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #18 on: Feb 08, 2014, 05:16:20 PM »
Doesn't this widen the front by 3"s too?

did you read reply #4? :slap:
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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #19 on: Feb 08, 2014, 06:17:14 PM »
Gonna ask another stupid ? Why the taco discs an not the one that fit the hub

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #20 on: Feb 08, 2014, 06:32:29 PM »
bigger is better  :biggthumpup:
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frm_808

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #21 on: Feb 08, 2014, 10:00:07 PM »
Gonna ask another stupid ? Why the taco discs an not the one that fit the hub
Taco is float, this way you don't have to remove the hub to replace the rotors

valon5150

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #22 on: Jun 18, 2014, 04:01:11 PM »
I was just trying to swap a taco booster and MC i had from an 01 v6 taco. booster is too large though, Clutch master and steering shaft are hitting it. did you use an earlier model taco or a 2.7 one?

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #23 on: Jun 18, 2014, 04:41:41 PM »
Good stuff :clap2: Got this thread added to our Tech from our Forum Members section on our store website!

Regards,
BigMike
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valon5150

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Re: Big Brake Mod (IFS Mod & Rear Disc)
« Reply #24 on: Jun 20, 2014, 04:04:11 PM »
solved my issue. massaged the lip/seem of the booster down right at clutch master and steering shaft with a hammer and it fits great now. Push rod was too short, easy to lengthen though.

 
 
 
 
 

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