2nd Gen Non-Engine/Transmission 3rd-Gen Front Brake Upgrade

[aharman]

Hi All,



Just thought I would post an FYI about putting 3rd-gen front brakes on 2000-2002 trucks.



I found myself in need of replacing front brake pads a couple of weeks ago, so before I acted, I did a search of the TDR Forums to check for 2nd-Gen brake upgrades. I found the link to the NorthWest Bombers forum, where one of the members had posted a picture-by-picture account of putting 3rd-Gen front brakes on a 2nd-Gen truck.



The parts that are needed for this are 3rd-Gen caliper brackets, rotors, and pads. The 2nd-Gen caliper works in this system without modification. It is also necessary on this conversion to have at least 17" wheels to get running clearance with the caliper. I bought the necessary parts from RockAuto.com for ~$260 dollars + shipping. It could have been even less, but I went with upgrade rotors and pads: Centric coated rotors (smooth), and Raybestos Advanced Technology pads. The brackets I got for $60 for the pair.



It took me about 2 hours per side to do the conversion, working outside in freezing Michigan weather. (This means I was running inside every 10-15 minutes to unfreeze my fingers. ) Everything fit as the pictures on the NWB site indicated, and I didn't run into any unexpected problems. The toughest part of the job is loosening and torquing the caliper bracket bolts, which have a 210 ft*lb spec.



Thanks to the TDR for steering me to this cost-effective upgrade!

 

[JKosten]

What was the link? This looks like a good upgrade

 

[aharman]

Here is the link:



3rd gen front brakes on 2nd gen - BOMBER Board

 

[Bob4x4]

IRRC that conversion requires a latter model 60 not the early ones many of us 2nd genners are stuck with

 

[aharman]

Yes, I think the NorthWest Bomber page makes it clear that the 2nd-gen truck must be a 2000 or later.

 

[JKosten]

Okay thank you.

 

[RMecum]

I'm so doing this!

I'm going to do this conversion next month. I've got a disc brake rear axel form the local truck dismantler that I'm having installed... . that swap is a little over my ability/tool level. But the front brakes I can do for sure. I read the NW Bomber thread and Vaughn MacKenzie mentioned that the 2009 brakes were even better.



My question is do the 2009's bolt up just a nice as the 03's? Man I can't wait to do this cuz my brakes can't suck enough.



Anyone done the 2009's yet?



Mike

 

[aharman]

I don't know if the 2009's fit, but the 2003 brakes are really, really good. They greatly increased the stopping power for a given pedal pressure. I haven't put very many miles on them yet because my truck sits for most of the winter, but I get a kick out of seeing the bigger rotors filling out my 18" wheels when I'm shoveling the driveway! Sorry to be such a nerd about this, but there's just something about doing an upgrade...

 

[RMecum]

Thanks for that info! I'm a couple weeks out on this and I'm hoping Vaughn might chime in or maybe I'll just PM him but nonetheless I'm gonna do it... 03 or 09's! Man I'm glad you posted this!



Mike

 

[RMecum]

Wheel size?

I just noticed you put 18" on wheels? Typo? I'm considering either some nice chrome wheels or 3rd gens... what did you do?

 

[Vaughn MacKenzie]

I'm going to do this conversion next month. I've got a disc brake rear axel form the local truck dismantler that I'm having installed... . that swap is a little over my ability/tool level. But the front brakes I can do for sure. I read the NW Bomber thread and Vaughn MacKenzie mentioned that the 2009 brakes were even better.



My question is do the 2009's bolt up just a nice as the 03's? Man I can't wait to do this cuz my brakes can't suck enough.



Anyone done the 2009's yet?



Mike

I checked Rock Auto and rotor & caliper part numbers are different for 2009+ than 2008 down. . . as to whether those are a direct bolt-on I have no idea. The info I read about the 2009 brakes being improved was from one of Steve St. Laurent's writeups here on TDR, but beyond that I just don't know.



aharman I see you have a 2wd, I haven't looked at the front suspension of the 2001 2wd I just bought. . . does the rotor just come off the hub or is hub/rotor combo? My '98 2wd has the old fashion style rotor/hub combo and when you service it you repack your own bearings. Rotors for '99 and older trucks are quite expensive.



I think I will do this upgrade on my /01 and see about using 2009/10 parts, hopefully the changes for '09 wasn't a suspension redesign where most parts are not interchangeable.



The reason this upgrade doesn't work for older trucks is Dodge made major changes for 2000 and nothing will bolt up to older trucks.

 

[Vaughn MacKenzie]

Looking at Rock Auto is there is less of a selection for '09/'10 brake parts and they're generally more expensive.

 

[RMecum]

Keep us posted!

Thanks for jumping in here Vaughn!



Depending on how busy (active Air Force Reserve) things get at work, it's probably going to be toward the end of Feb before I get to this... maybe even later so I'll be looking forward to what you find out.



Mike

 

[hammersley]

this sounds great - WHAT about the 4500/5500

brakes - I assume the front end is different?

 

[aharman]

You need at least 17" rims to clear the 2003 front brakes. Since I had put 18's on my truck years ago, it was no problem.

 

[aharman]

Hi Vaughn,



Yes, on 2wd's the rotor comes off the bearing hub. My conversion went just as depicted on the NWB forum. I did have to use a big hammer to drive the rotor off the hub due to corrosion.

 

[Vaughn MacKenzie]

Hi Vaughn,



Yes, on 2wd's the rotor comes off the bearing hub. My conversion went just as depicted on the NWB forum. I did have to use a big hammer to drive the rotor off the hub due to corrosion.

It's good to hear a Big Hammer should do the job because I don't own a BFH :-laf

 

[RAJohnson]

Vaughn, I have a BFH you can borrow.

 

[aharman]

Actually, I had to go out and buy a BFH to do the job.

My FH wasn't B enough.

I was PO'd that I had to make a separate trip to the store.

I got the B-est FH that they had: 4 lbs. Not 3 lbs. 4.

I taught that rusted rotor a lesson it will never forget.

 

[WalterRyan]

Do the DRW trucks also need to use 17 inch wheels? I am needing front rotors and would like to do this but the 17 inch tire selection is not as good. I want to go back to Michelin XPS tractions but they do not list a 17.