DANA 60 Rear Disk Conversion - Trucks 4x4 @ Off-Road.com
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DANA 60 Rear Disk Conversion
Publish date: Jan 25, 1998
By:  James Oxley
Source: Off-Road.com

72-79 FORD DANA 60 REAR DISK CONVERSION

Note:
You can click on any image to download the FULL SIZE picture.
Figure 1
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:
  1. Caliper brackets (1/4" flat steel plate)
  2. Caliper bracket mounting hardware (4 nuts, bolts, washers)
  3. 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.
Figure 2
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.
Figure 3
Notes on installation.
  1. 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
  2. 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.
  3. 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.
  4. Figure 4
  5. 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.
  6. 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.
  7. 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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Source: Off-Road.com, 1/25/1998
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