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Early Bronco Restoration - Bronco Connection LLC

We offer a complete disc brake kit that will work to convert nearly every drum brake Dana 44 or Dana 30 axle no matter what the vehicle it may be installed in. Follow our step by step installation instructions.

Contact us if you have any questions.

Our comprehensive disc brake conversion kits include all the parts needed for a trouble free backyard or driveway installation.

Unlike some of our competition, our kits include all of the needed parts. No need to run back and forth to your local parts store. Everything is here: Backing plates, rotors, hubs, spindles, inner spindle bearings, dust seals and thrust washer, wheel studs, inner and outer wheel bearings, hub seals, calipers, brake pads, Lockout hubs and caliper hoses.

Everything is new and as is shown in the following pictorial, easily installed with normal common hand tools.

We are showing a early Bronco Dana 44 for this example. The process is the same for the early Bronco Dana 30 as well.

Remove the lockout hub retainer bolts

Remove the outer snapring

Remove the inner snap ring

Now remove the locking hub mechanism.

Now pull the spring out of the hub.

Remove the outer spindle lock nut

Remove the spindle lock ring.

Use a socket designed for the Dana 44 spindle lock nuts to properly remove and replace these nuts.

Use the socket to remove the inner lock nut

Now remove the hub and drum assembly.

Remove the brake backing plate bolts then remove the backing plate after disconnecting the steel brake line from the brake cylinder

Now remove the drum brake spindle.

Now you can remove the inner axles if you wish. This may be a good time to replace the u-joints while you have the assembly apart. Otherwise you can leave it in the knuckle.

We have rebuilt this axle used in this example. You should clan up the knuckle where the spindle attaches

Install the inner axle

The new spindle includes inner spindle bearing, thrust washer and two inner dust seals

Using a good high temp wheel bearing grease, grease the inner spindle bearings and seal, Place the seal in the spindle with the lip up. Grease the lip liberally.

Install the outer dust seal on the axle slinger and grease it liberally.

Then place the thrust washer onto the inner stub axle with the bevel towards the seal. Grease both sides of the washer.

Seal and thrust washer installed correctly and greased.

The spindle is now ready to install

Now the caliper bracket is ready to fit and install. reuse the brake backing plate bolts from the drum brakes.

Now you must fit the caliper to the bracket. Mount the caliper and slide it out on the bolts. You will see where the caliper will hit the knuckle. Mark this area, it must be removed with a grinder to give adiquate clearance so that the caliper does not hit it.

A simple side grinder will work very well for this.

Remove the backing plate and grind the area as shown until the caliper has clearance.

Now there is plenty of clearance. This is a very easy procedure that anyone with a grinder can perform.

Just make sure the caliper can travel the full length of the mount bolts without touching the knuckles. Here the caliper is in against the caliper bracket.

Here the caliper is extended out to the end of the bolt. The knuckle was gound properly with enough clearance for the caliper.

Now we finish the hubs and rotor assemblies

Fill the internal void with good quality high temp wheel bearing grease.

Pack and install the wheel bearing

Click here to add text.

Install the hub seal.

Grease the inner bearing race

Pack the outer bearing and install in the hub.

Install the lock nut to 50 ft lbs, then the lock washer with the tab and slot aligned, last the outer lock nut to 50 ft lbs.

Spin the tightened hub to make sure the rolling resistance in not too tight or loose.

Install the inner locking hub mechanism into the hub

Install the outer snap ring

Install the outer hub and tighten the bolts.

Now we can load the calipers with pads. Install the pad springs on the back of the inner pad.

Install the pad set in the caliper.

Install the caliper and tighten the bolts to 35 ft lbs.

Install the caliper brake hoses and the installation of the disc brake kit is complete. Bleed the brakes properly.

To get the full effect and power of the disc brake system we suggest one of our power brake systems. These are also boly on kits. Check our parts store for more details on these parts.