T-Case Mounted E-Brake - DONE

[Grape Ape]

Hey everyone,

I know some of you have asked about how I did my t-case mounted e-brake setup, and here it is:
(Oh, sorry for all the yelling.....that's how it copied in!)


I USED THE DISC AND CALIPER THAT ARE AVAILABLE FROM "ALL-PRO OFF-ROAD", ON TOYOTAS.

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THE EXISTING MOUNTING HOLES IN THE DISC HAD TO BE WELDED IN AND NEW HOLES DRILLED TO FIT THE STOCK FORD FLANGE. (TOYOTA'S HAVE A ROUND PATTERN, BUT FORD'S IS RECTANGULAR) MAKE SURE THE DISC IS CENTERED PROPERLY, OR SEVERE VIBRATIONS CAN OCCUR. THE PICTURES SHOW HOW THE BRAKE DISC IS MOUNTED BEHIND THE FLANGE ON THE EXISTING BW-1354 T-CASE.

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THE CALIPER MOUNTING BRACKET IS MOUNTED TO THE REAR OF THE BW-1354 USING THE EXISTING FOUR BOLT HOLES ON THE REAR OF THE T-CASE. SOME RANGERS / EXPLORERS HAVE A COVER OVER THIS AREA, WHICH IS NOT NESSECARY. (sorry, not the best picture)

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THE LINKAGE USES 3/8" THREADED ROD, WITH 3/8" HEIM JOINTS ON EACH END. THE EXISTING E-BRAKE CABLE WAS SHORTENED AND TIED INTO A PIVOT, WHICH ONE END OF THE ROD/HEIM IS ATTACHED.

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(sorry, no picture of pivot bracket)
WHEN THE FOOT PEDAL IS PRESSED, AND CABLE PULLS ON THE PIVOT, WHICH TURNS AND PULLS THE LICKAGE THAT IS ATTACHED TO THE CALIPER, TO SET THE BRAKE.

THIS SETUP HAS A MUCH STRONGER HOLD THAN A STANDARD REAR AXLE DRUM E-BRAKE.

Dean

 

[410Fortune]

Nice work!

So I guess it is not possible to use the cable to set the caliper?

Man you take the thoughts right out of my head and use them on your truck!

That is one badass Ranger........wouldnt mind seeing it in the Tough Truck..........

 

[Grape Ape]

Hey 410,

It may be possible to use the cable, but you would have to make a curved cable runner/track to keep it from binding.
This way just seemed easier.

I wish I had the $$ and support team to go to TTC, but I know the truck wouldn't last very long with only a D44 and 36 or 38" tires. Plus, I hate mud!!

Dean

 

[Black Magic]

Looks like a good install. Is the purpose just for a more secure break.

 

[V8BoatBuilder]

What about stress on the u-joints and diff? I take it the old e-brake was removed to get rid of the cable. Do you have a locker? Otherwise, won't the wheels still spin?

 

[Grape Ape]

Black Magic,
I swapped out axles, so I am now running a D44 front and a Dana 60 rear axle which was converted to disc brakes. I could not find a set of calipers (cheap, I should say), with an e-brake latch, to match the thickness of the new rotors. So the only other option was a driveline brake. NC does not allow line locks as an adequate e-brake for inspections.

V8Boatbuilder,
I don't know all the physics knowledge or math to give you actual facts, but I know it is stronger from stuff that I've read. Something about the difference in the circumferences and fricion forces.....blah...blah. Sorry, wish I had a better reply. As for the wheels spinning, even if the tranny isn't in gear, the driveshaft won't spin. I do understand your question, and I really don't know the answer. I'm guessing only one wheel COULD turn if you didn't have a locker, because the driveshaft is connected to the pinion, which would keep the ring gear and at least one wheel from spinning. Good question. That needs some researching, or someone that can answer it.

Dean

 

[DasFrem]

Install looks great, I'd like to do that myself one day, way down the road. I've got another quesiton that's sort of off topic for this thread, but where did you get the disc brake conversion for the D60? I'm picking up one out of a j30 with 5x5.5 for when I do my SAS but havn't seen a conversion kit for it.

 

[Grape Ape]

DasFrem,

It wasn't really a complete conversion kit, but more or less a combination of parts that I knew fit together, after researching the subject. Since I have a 1 ton Dana 60 rear axle, it is an 8 lug pattern. I used 8 lug rotors from a 3/4 ton Chevy Dana 44 front axle, which fit perfect with the D60 hub. I used the calipers from the same 3/4 ton Chevy D44, and mounted them on the axle with a premanufactured weld-on caliper mount from A&A Manufacturing ( http://www.aa-mfg.com ).
The Dana 44 rotors are about 1-1/4" wide! That is why I couldn't find other calipers to fit them. There are some more pics of the setup on my site, in the "Old Pics" section.
There are several places out there that make a kit, with or without calipers, but look to spend at least $400 for it, not including the calipers!
You should be able to find discs and calipers that will work for your conversion. Possibly Ford Expeditions run the 5 on 5.5 bolt pattern, and have rear disc brakes. I'm not certain, but could be a possibility. Or any other vehicle that has rear discs, and a 5.5 pattern should work, with a little modification.

Hope that helps,
Dean