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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 bolt-on conversion with no welding required. 1984 - 1989 Cherokees and Comanches with a Dana 44 or a non-c-clip 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 Brake Con... Which Rear Axle do you have?: • How to Identify Which Rear Axle You Have -... What is Brake Bias and why is it important?: • Why are Front Brakes Larger than Rear Ones... Why bigger brakes won’t actually stop your car faster: • Why Big Brakes Won't Stop You Faster but W... Thanks to Bryant for his knowledge and assistance on this project: / @xj_overlander YOU WILL REQUIRE: -03-07 KJ Backing Plates -03-07 KJ Backing Plate to Axle mounting studs -03-07 KJ Parking Brake shoes and hardware (new) -03-07 KJ Rear Brake Rotors & Pads (new) -03-07 KJ Rear Calipers & Banjo bolts (new) -99-04 WJ Rear Rubber brake lines -84-01 XJ Dana 30 wheel studs (x10) -93-98 ZJ Proportioning Valve Spring -97-01 Disc Brake compatible Parking Brake Cables -84-01 Pre-Flared Brake Lines 12” & 40” -97-01 XJ Front Parking Brake Cable & Equalizer -91-04 XJ Rear Axle Wheel Bearing TIMKEN 6408 -91-04 XJ Rear Axle Wheel Seal TIMKEN 8835S -97-07 XJ Differential Center pin bolt -91-07 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 -Needle-nose 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?... -97-01 XJ Rear Disc Swap Parking Brake Cables: https://www.quadratec.com/p/crown-aut... -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] fro... 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