2nd Gen Non-Engine/Transmission 02 brakes on a 96

[RAndrae]

Well I got it done today. I put a 02 disk brake rear end, master cylinder and all the hydraulic assist parts in my 96 1 ton dually. finally firm good brakes. every thing bolted right up even the 99 power steering pump. Same as the 96 but has all the plumbing for the hyd assist. All went well with only a couple of mods needed. e brake cable needed to be shortened and needed to make a couple of brake lines from the proportioning valve to the master cylinder. Just FYI there is a considerable difference between the sizes of the Master cyl pistons, I knew there would be due to the 4 wheel disk brakes but just surprized- about an 1/8 inch!

Also put on a ATS manifold, PDR HX 35, 16 exhaust housing and 3000 GSK WOW what a diff from the # 12 plate I had.

 

[Dkuhlman]

I was amazed at the improvement in brakes between my '94 and '02. If the 3rd gen brakes are that much nicer, they must be some real anchors!



Had to have the wife drive the 'ol '85 suburban this morning as her car had a flat and the ctd wasn't plugged in (wind chill 0 F this morning at the beach!) I warned her not to tailgate as she is not used to driving it. Talk about weak brakes!!!



Glad your conversion worked out.



Don

 

[BKenny]

I have an 01 and i would like to swap out my rear drums for discs. What was involved in the rear

 

[RAndrae]

rear disks

Well I was originally going to buy the disk conversion kit but decided to look for a 02 rear end, got lucky and found one. It bolted right up, everything the only mod I had to do was shorten the ebrake cable. I had to find a place the would re swedge an end on but other than that direct bolt in. I ran the disk rear end for several monthes b4 I converted the hyd assist and 02 master cyl. It worked ok but had a very mushey petel. When I put the hyd assist parts in they bolted right up even the 99 power steering pump.



The hard part was the brake lines. I used the 96 anti lock valve and proportioning valve. The proportioning vaves appeared the same internally but the treads are different. so all I had to change was the lines from the proportioning valve to master cyl. The 96 is standard tread with flare ends. The 02 is metric lines and metric fittings and double flare ends. I bought a double flare tool from Eastwood. I had the proportioning valve to master cyl lines from the 02 and used then to make my lines I needed.



It seems that it would make sense to use a 02 mastercylinder when a disk brake swap is done like I posted earlier the piston is alot bigger.