Note:
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I recently installed a DANA 60 with rear disk brakes in my 1978
Bronco. There are supposedly 23 different versions of the DANA 60
rear end. You will need a DANA 60 from a ¾ ton ford from 1972
through 1979. This rear is a bolt in, except for driveshaft length
and u-joint size. It is possible that ford used this type of rear
up to 1984, but sporadically. You will know you have the correct
DANA 60 if the brake drum is mounted on the back side of the hub
(just like the front rotors on a DANA 44 front axle). For the FORD
purest, I suggest you stop reading now, as your not going to like
what you hear next. I used a kit from TSM (a.k.a., The Streetrod
Mfg. Co., Inc.). the basic kit cost $279.95 and consists of:
Rotors (gotten from the front of 3/4 ton mid 70's-80's 4wd
che*bbie)
I also got rear calipers from TSM. They cost $300.00 and are taken
off a 76-78 Cadillac Eldorado. These calipers have an integral
parking brake. To enable removal of the caliper, I also ordered the
optional stainless steel brake lines. These were $70.00.
Just a note on prices. The basic kit is available without the
rotors. The rotors and calipers may be found cheaper at your local
auto parts store. It basically depends on the core charge for the
calipers, which I found varied wildly from $3 to $78. Here is what
the setup looks like completed.
Notes on installation.
I originally installed calipers upside down to allow parking
brake mechanism to be on upper side of caliper. I had to gravity
bleed calipers before I installed them. Stock emergency brake
cables fit this way on 78-79 Broncos. The emergency brake cable
bracket had to be modified by welding on a 3" long plate. I
consider this to be the biggest drawback to the entire kit.
Calipers were later installed right side up to facilitate normal
bleeding. With calipers right side up, emergency brake cables had
to routed under axle. Passenger side fits, but drivers side needed
an 8" extension. I sent cable as template to Custom Cables Inc.,
1-562-802-1122
Calipers were supplied with aluminum and brass washers for
banjo bolt connecting stainless line to caliper. Aluminum washers
crushed too easily allowing brake fluid to leak. The old tried and
true brass washers worked fine.
I had just bought brand new 15" Super Swampers. 15", 8 lug
wagon style wheels are available from American Racing. Outside part
of calipers needed to be ground 1/16 of an inch to allow mounting
of 15" wheels. See picture for clearance (it's not much) of wheel
and caliper.
I did not need a proportioning valve. The 10 psi residual valve
is left in to ensure the brake pads stay seated against rotors. GM
rear calipers need parking brakes adjusted correctly to keep pads
against rotors. Parking brake should also be used regularly to
ensure it won't freeze up.
I can now lock up the rear brakes with 38" Super Swampers. The
overall brake feel is still spongy, but braking is much better than
before. I will be installing a 1979, F350, 2wd, booster and master
cyl. These are supposedly a bolt in on 78-79 Broncos and help with
spongy, long travel brakes.
SS brake lines use a banjo fitting for a 7/16 inch banjo bolt.
The opposite end of SS line is an AN-4 fitting. AN-4 to female
flare tube adapters are needed to complete the conversion. I custom
made new hard lines for both sides of axle assembly. 14" SS lines
with banjo fitting and AN-4 fitting on either end can be had for
$10.00 through some racing catalogs.
Send any Questions or Comments to: James Oxley
Last Updated: January 25
th,
1998
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