Bronco Brake upgrade options

[dtbback]

While workong on my DD the other day I had a thought, which has lead to a question for the gurus out there. Has anyone considered using 2003-2006 Lincoln Ls rear calipers and the 1982 CJ5 rotors for a 9 inch rear disc coversion. I ask for several reasons:

1. The Lincoln Ls tips the scales at near 4000 lbs. I have one. She's a hefty but comfy girl.
2. The Lincoln LS Rear calipers have a built in cable operated parking brake.
3. The front rotor thinkness on the 82 CJ5 rotors matches perfectly with the Lincoln LS calipers.
4. Lincoln LS calipers can be had for 65.00
5. I've never had an issue with my parking brake pn my Lincopn LS

[arse_sidewards]

While workong on my DD the other day I had a thought, which has lead to a question for the gurus out there. Has anyone considered using 2003-2006 Lincoln Ls rear calipers and the 1982 CJ5 rotors for a 9 inch rear disc coversion. I ask for several reasons:

1. The Lincoln Ls tips the scales at near 4000 lbs. I have one. She's a hefty but comfy girl.
2. The Lincoln LS Rear calipers have a built in cable operated parking brake.
3. The front rotor thinkness on the 82 CJ5 rotors matches perfectly with the Lincoln LS calipers.
4. Lincoln LS calipers can be had for 65.00
5. I've never had an issue with my parking brake pn my Lincopn LS

So it's basically the same design as the shitty GM caliper but not shitty?



FWIW 4000lbs isn't exactly fat for a modern sedan. It's thick, but not fat An '09 Altima is in the high 3000s just as a reference point and that's a "midsize" sedan.

[dtbback]

Screenshot_2015-11-17-15-07-35-1.png (521.95 KiB) Viewed 1886 times

Here's a pic. The mechanism looks much stronger than the GM version.

[birdco85]

Those have a 43 mm piston. I'm using ones from a Thunderbird, like PaulW, and those have a 45mm piston. Mount the same. Also the same as some year mustang gt

And also, the cj rotors have huge Lug holes, so unless you get the Od of your axle flange the exact same as the id of the rotor hat, you will have centering issues. You could drill and tap for those flat head screws that most imports run but then you would have to perfectly duplicate those holes if you ever need to replace the rotors.

I ended up getting front rotors from a 2000 Kia sportage. They have 1/2" holes already so they would fit perfect on stock lugs.

I have 9-16" studs so I just drilled mine over using a
Unibit and they work perfect. They're now Lug centric and I don't need to worry about centering. They are also thicker than the cj rotors.

Just a thought for you.

[dtbback]

What year thunderbird did you source your calipers from?

[birdco85]

88. They have the correct parking brake cable fitting so you don't need special cable ends. You would just need to make a mount for the actual cable to keep it the right distance from the caliper. PaulW originally told be 1990 for the caliper but they have a funky p brake hookup and wouldn't work without new cables.

[dtbback]

Thanks for the info!

[birdco85]

Si guey.

I will say, I wish I would've just done the Chevy caliper. It's a lot if research and misspent money to find the correct parts. I'm glad I did it but Geez the Chevy would've been so much easier. All for me to keep a parking brake.

I should have just went with a sense swedgelok ave called it a day.

[PaulW]

88. They have the correct parking brake cable fitting so you don't need special cable ends. You would just need to make a mount for the actual cable to keep it the right distance from the caliper. PaulW originally told be 1990 for the caliper but they have a funky p brake hookup and wouldn't work without new cables.

=========
Mine use a spliced cable Works fine when using nikopress
Stock up front and rear is new for each side.

[arse_sidewards]

Yes or no question, can an off the shelf 88-tbird caliper work with the stock cable setup?

[toddz69]

Don't know the answer to the cable setup compatibility but when you're asking for the '88 T-Bird rear calipers, they're for the Turbo Coupe. That's the only model with rear discs (also used in '87).

Todd Z.

[birdco85]

Yes or no question, can an off the shelf 88-tbird caliper work with the stock cable setup?

They're setup for 1/8" cables so you would need to spread them open a tiny bit too get the bronco 3/16" cables to fit in, but the end for perfect in the seat. You need to make a small bracket to keep the slack out of the cables, hard to explain but a piece of angle that the cable can run through would work. I'll see if I can dig up a pic.

Don't know the answer to the cable setup compatibility but when you're asking for the '88 T-Bird rear calipers, they're for the Turbo Coupe. That's the only model with rear discs (also used in '87).

Todd Z.

You are correct sir. Forgot to mention that.

[PaulW]

Yes or no question, can an off the shelf 88-tbird caliper work with the stock cable setup?

=
Aftermarket at the caliper end. I bet i could put a custom end on the stock cable? Aircraft Spruce selsl the fancy custom ends and the imitation niko hand held squeezer. I use that squeezer all the time.

[birdco85]

This is what would need to be made. The little angle bracket that the actual sleeve portion of the sleeve would attach to. The caliper has a spot to attach the cable but the distance between it and the actual parking brake lever is about 1.5-2". If you picture your drum brakes, the distance from where the cable attaches to the backing plate to where the cable attaches to the actuator bar is about 4". So you need to mount this little angle bracket to make up the distance. Hope that makes sense.

[PaulW]

Rear caliper cable attach
Since words don’t cut it see the pics
Go to the auto store and get two cables that have ends as shown, Cut the cable to your length and splice to the front half of the stock cable using the aircraft cable splicer tool and copper ferrules (one will be plenty strong enough, but I use two). Cables are 1/8”. Go to Harbor Freight and buy the storehouse box of circle clips because you will probably break one or two as you mess around.
So two back cables each spliced as shown. And the balance bar is stock as shown and is part of the front cable. New rear cables are different lengths and note that the ends at the caliper is the same as stock at the stock balance bar. Measure lengths to suit your routing and leave extra slack on the passenger side.
Pics shown in a random order. If you cannot find a new cable try using JY stock cables flipped and cut to length.

[birdco85]

Paul

When you say get 2 stock cables, are you referring to Thunderbird cables? That makes sense to crimp them together. I like that way better so you don't need any bracket to hold the cable further away. I was suggesting that due to how ssbc does their kit.

[birdco85]

And thank you for the pictures. Do you have your calipers mounted pretty low? It seems they're about at the 4 o'clock position.

[PaulW]

Paul
When you say get 2 stock cables, are you referring to Thunderbird cables? That makes sense to crimp them together. I like that way better so you don't need any bracket to hold the cable further away. I was suggesting that due to how ssbc does their kit.

= ==
I did not do the install. For you remove the Bronco cable from the balance and reverse it and put it on the caliper. I am pretty sure it will fit. Break the gadget that holds the cable to the front bracket and when you reinstall use a regular C clip. When you discover the Bronco cable fits the caliper then go get 2 more from the JY or auto store.

[PaulW]

And thank you for the pictures. Do you have your calipers mounted pretty low? It seems they're about at the 4 o'clock position.

= = =
Mount the caliper so the cable has a straight shot to the cable/caliper attach and passes under the housing. Different housings dictate the clocking of the caliper. Mine is low because of the huge full floater Tubeworks housing. My spring constantly catches twigs, but has never been harmed.

[dtbback]

I ended up getting front rotors from a 2000 Kia sportage. They have 1/2" holes already so they would fit perfect on stock lugs.

Did you end up having to grind your axle flanges with the Kia rotors?