2nd Gen Non-Engine/Transmission Disk Brake Upgrade & Axle Swap

[CrewCabDiesel]

After reading all the issues on rear disk brake conversions I decided that the OEM setup was the way to go. I have an early 2001 3500 4X4 (build date Jan. 2000) that has rear drum brakes. If the truck had been built 6 months later it would have had rear disk brakes from the factory. I just lucked out and bought a 2002 dually limited slip 3:55 dana 80 with OEM disk brakes. I will be swapping out my the drum brake Dana 80 for the new rear disk Dana next weekend (weather permiting). Does anyone know what other componets that are different from the disk brake 2001 from the drum 2001? I checked with the dealer and found out that the master cyclinder, brake porpotioning valve and ABS pump are both the same. Any suggestions on this swap would be a great help.

Thanks

Kyle

 

[dan_gilson]

I don't know much about this but I do know a little.

I have a 98. 5. My dad has a 2001 with rear disks. The front axle is also different in that it has 2 piston calipers. I also notices that the master cylinder has a much larger resiviour. I suspect a different master cylinder too.



I would play 20 questions with a dealer about differences in parts on the master cylinder.

Also ask whether there is a different "program" or firware for the ABS. You may need to get it re-flashed too.



There may be clearence issues for the rear wheels too. Make sure that you can bolt up a wheel before swapping.



My dad's 2001 feel so much better on the pedal than mine. I have been think about doing what you are doing for a while.

 

[Dane]

I checked with the dealer and found out that the master cyclinder, brake porpotioning valve and ABS pump are both the same

I find it hard to believe the proportioning valve is the same for discs and drums.



Check out www.mpbrakes.com for good info.



Keep us posted on your progress...

 

[Ramafid]

I was going to do this swap on my truck. I got all of the parts from the dealer took everything apart and guess what? Since my truck was an early Y2K ( Aug 99) I still had the old flange design for the rear axle. Brake swap was a no go. I was pretty bummed because I wanted to stay with just OEM parts. So I still have my drum brakes and will have to be satisfied. Good luck with your swap. You should not have any problems.

 

[CrewCabDiesel]

I am concerned about the software on the ABS computer, forgot to ask the dealer so if anyone knows if there is different software for the 4 wheel disk, please let me know. It seems on the 2000 to 2002 Dodge 2500 & 3500 trucks the brake system is the same with the exception of the use of rear disk brakes starting in 2001. 5 .

I was suprised to learn that Dodge was still using single piston calipers on the front up to 1999 trucks. I know my 2001 has dual piston calipers on the front and soon the OEM rear disk calipers will be also dual piston as well.

I still have to get a set of new axle U bolts, and some more Royal purple 75W140, I then should be ready to do the swap. I hope to get it done this coming weekend before my wife blows a gasket. The garage is starting to look a lot like a junk yard and I have got to get my single car garage cleaned out before the snow hits my wifes SUV. I now have in the garage 2 dually tailgates, an extra dana 80 axle, bunch of 65 Barracuda parts, a set of 7 Michelin tires, not to mention all the extra dodge truck parts. So some of the stuff looks like ebay fodder .

 

[CrewCabDiesel]

Well the swap is done, and the old dana 80 is now on ebay, and would you believe it works GREAT . The OEM rear disk brakes kick butt, no problems with the master cylinder or the ABS computer. I took the truck down a dirt road a slammed on the brakes and the ABS work better than ever . On pavement it now stops on a dime and gives change !!!!! One thing that does not fit is the park brake cables and bracket. Right now the park brake cables are wire tied to the frame until I get to the dealer to order parts, looks like I will need the middle park brake cable and a mounting bracket. Other than that it was a complete bolt on and I had it done on 4 hours and it was well worth the effort.

Kyle

 

[redfuelrules]

Hi All, does anyone know if factory discs from an 01. 5 srw would bolt directly on to a 01 d80 dually, like the one Kyle no longer has a use for?

 

[CrewCabDiesel]

redfuelrules,

I wish I could say yes but the ends of the axle housing are different. Someone did the conversion but it required some welding. Since you already have the disk set up you may be able to weld the end plates from one axle to another(drum axle backing plate bolt holes are in a shape of a square, the disk brakes mounts are wider at the top than at the bottom). You will need to get the dually rotors and hubs, but I believe the disk brake backing plates and calipers are the same from 3/4 to one ton. In short I did a bunch of research for a OEM disk brake conversion on my old axle and I decided it was not worth the grief(I didn't have a source of parts and templete like you do). If I had not tripped over this disk brake dana 80 axle I would have never done the conversion. A Dodge Dually Dana 80 with disk brakes was only made from 2001. 5 to 2002 and I never thought I would find one that I could afford to buy.

Kyle

 

[Dachenbach]

I've seen a couple aftermarket kits available for drum brake trucks. You mentioned a lot of issues with doing disc brake convestions. Are the aftermarket set-ups a waste of money?

 

[CrewCabDiesel]

That topic is almost is hot as what type of oil to use . I have seen different types of rear wheel disk conversions, but none seem to have a 2 piston heavy duty caliper and a good park brake(some even use the calipers from a caddy with the park brake built into the caliper, those were junk then and are junk now). After looking around I did not see any aftermarket setup that was worth the cost, but is just my 2 cents. If I had had another dana 80 with disk brakes to use for parts and measuring I would have converted my orginal drum dana 80 to OEM disk brakes long ago. You might want to do a search on rear disk brakes.

Kyle

 

[JBrehaut]

does anyone out there know of an upgrade for a 96' 3500 4x4 dually? pads,rotors&and calipers? i bought this truck a year ago and owner said new pads and rotors were installed. in the hills of bisbee,az. , i found this not to be true as it started making a grinding noise and dash lights lit up like the 4th of july fireworks i came to see. i've heard from other owners stating that this is a commen problem with the dodges. any answers out there?