TJ Rear Brake Upgrade

Jeff_R said My parking brake won't hold my 04 TJ on steep slopes. I have adjusted in several times the past (internal adjusters and cable tension adjuster) but it is still and issue. I had it looked at by a really good shop near me and he said that the the brakes are really small. My Jeep was originally an X, not a Rubicon. Are the rear brakes different on the X and the Rubicon models?

I'm thinking of upgrading my rear brakes and would appreciate any recommendations, ideally as specific as possible, about upgrade options. I know ther are some brake upgrade and conversion kits but I have no idea what is best. Also, how hard is it to do it yourself? TIA!

Hey Jeff,

It all depends on what rear end you are running now, the 04 X model had a Dana 35, the Rubicon had the 44.  I don't remember what rear end you are running but I'm pretty sure its not the dana 35.  That being said, it is difficult to get the emergency brake to work well on any of the wrangler disk brake rear axles, they are tiny shoes inside the hat rotor and take a lot of work to get into adjustment properly.  That doesn't mean it cant be done but it takes alot of adjusting between the drum and the tension cables going to the hand brake.  This is mostly because your emergency brake and your braking system are totally separate.  You really only need a brake upgrade if you go up to 1 ton axles and/or are carrying alot more weight.  As long as your brakes are working when you are driving around you shouldn't need an upgrade, although i did see an upgrade that gives you larger rotors and calipers that can utilize the same master cylinder.  I would be more than happy to help you with them if you want, just let me know.

Thanks Jase. I should have mentioned that I do have a Dana 44 in both the front and the rear but I have the original drum brakes in the rear and the original disk brakes in the front. I believe the Rubicons had rear disk brakes in the 04 model year. I never rely on my parking brake on any moderate to severe slope. I always shut the vehicle off and and keep it in gear when I get out. My brakes have me concerned for two reasons. One as mentioned, the parking brake. The other issue I have had is having my brake pedal go all the way to the floor on the trail (never on the road). This happen several times on the Rubicon and once up at Sierra Trek. I also feel like it isn't braking as well on the road but I don't think this is too bad.Thanks so much for the offer to help if I do upgrade them. I'm not the most skilled mechanic and I don't think I would be comfortable doing anything more on brakes than changing pads and shoes.

Hey Jeff, I would check out Black Magic Brakes and see if they have any solutions for you. The main guy Blaine, really knows his stuff for TJ brakes. https://blackmagicbrakes.com/

I wouldn't hesitate to call and ask if you don't see what you need exactly.

Hey Jeff,

https://wranglertjforum.com/threads/are-dana-35-and-dana-44-brake-rotors-the-same.22496/

If you and Jase are going to work on it I wouldn't mind being there to help.

Jeff_R said Thanks Jase. I should have mentioned that I do have a Dana 44 in both the front and the rear but I have the original drum brakes in the rear and the original disk brakes in the front. I believe the Rubicons had rear disk brakes in the 04 model year. I never rely on my parking brake on any moderate to severe slope. I always shut the vehicle off and and keep it in gear when I get out. My brakes have me concerned for two reasons. One as mentioned, the parking brake. The other issue I have had is having my brake pedal go all the way to the floor on the trail (never on the road). This happen several times on the Rubicon and once up at Sierra Trek. I also feel like it isn't braking as well on the road but I don't think this is too bad.Thanks so much for the offer to help if I do upgrade them. I'm not the most skilled mechanic and I don't think I would be comfortable doing anything more on brakes than changing pads and shoes.

Jeff,

I have the same in my 98, the 44 with Drum brakes, I also will never trust the Emergency brake.  I need to adjust mine again, but it never makes me feel comfortable on a hill, I also always shut down and put the transmission in gear.  The pedal going to the floor is pretty concerning, even just the pedal feeling mushy is not good, that shouldnt be happening even with the rear drums.  I dont ever feel like i have trouble stopping and im running 35's, if i stomp on it it will lock them all up and no mushiness, even with the jeep is overloaded the brakes have worked well.  I will eventually change out to disk in the rear just because they are so much easier to work on.  Any time you need any help on your jeep feel free to let me know, I am more than happy to help out and that goes for you too John.  I was just getting ready to strip down the TJ and I got my registration notice and have to smog it, so I may just change the hoses and thermostat and clear the codes and go get my smog, then Ill strip it down, im going to pull the head and check the valves and do the timing chain and pull it all back together with new gaskets and new radiator and electric fan.

Thanks Jase,

I do a lot of work on my TJ myself and have collected a lot of tools in doing so.  So if you need something I may have it (20T Press, Slide Hammer, Cylinder Leak Tester, Ball Joint Separators and Service Kits, Transmission Jack, etc)

So if you need an extra hand also don't hesitate to reach out.

My next big project is installing an EVO Long Arm Kit with King Coil Overs in my JK.  Debating doing it myself but a shop is going to want $$$$.

Sloguy said Thanks Jase,

My next big project is installing an EVO Long Arm Kit with King Coil Overs in my JK.  Debating doing it myself but a shop is going to want $$$$.

We haven't had a club build party in a long time, right Jeff and Greg. I'm willing to help.

I had the rubicon 44 with the disc brakes and the e-brake is something like 7” diameter by 1” wide vs 9” diameter by 2” for your factory rear drums.

going to a rear disc setup will help on the road and trail but your e-brake will be smaller. If you are ok doing a pick-and-pull run for new backing plates, some YJs, some early XJs, and some MJs had tow package brakes that were a 10” diameter by 2.5” wide drum. Without doing rear discs and a line-lock I don’t see any stronger e-brake options

And the pedal going to the floor means you are due for a new booster/master cylinder. Rubber only lasts so long and ~20yrs seems like a pretty good life for the internal seals. If you go rear discs then get the rubicon booster/master/proportioning valve, if drums then factory replacement

Jeff_R said

Sloguy said

Thanks Jase,

My next big project is installing an EVO Long Arm Kit with King Coil Overs in my JK.  Debating doing it myself but a shop is going to want $$$$.

We haven't had a club build party in a long time, right Jeff and Greg. I'm willing to help.

I'm always down to help with a build party. I'm just not sure I'm the help you want. 🤡

Where's the other Bakken brother when you need him 😇

Just remember, you started it

I'm always down to help with a build party. I'm just not sure I'm the help you want. 🤡

Jamie (K6NUB) said Where's the other Bakken brother when you need him 😇

Just remember, you started it

I'm always down to help with a build party. I'm just not sure I'm the help you want. 🤡

I know, right!?! He was so good at fixing things...I miss him too.

Kathleen and I are always good at getting the pizzas for these parties!!!

L  👧

Lynda and Guy said Kathleen and I are always good at getting the pizzas for these parties!!!

L  👧

You gals are great at yard work also if memory serves me right. 👍

Ha ha ha! Oh yeah I forgot about that. We do amazing things when we get bored!

Now it sounds like my throw out bearing is shot. There is a loud, high pitched squeal when I press in my clutch pedal. I made an appointment with my local mechanic but he can't get me in until September 11th. Looks like I will need a new clutch, etc. I'm hoping I will get it back on the 14th to be able to make the Barrett Lake run but I might have to miss that run. I still need to figure out what to do about my brakes. Looks like my TJ is staring to show its age but it still has less that 90,000 miles on it.

Jeff_R said Now it sounds like my throw out bearing is shot. There is a loud, high pitched squeal when I press in my clutch pedal. I made an appointment with my local mechanic but he can't get me in until September 11th. Looks like I will need a new clutch, etc. I'm hoping I will get it back on the 14th to be able to make the Barrett Lake run but I might have to miss that run. I still need to figure out what to do about my brakes. Looks like my TJ is staring to show its age but it still has less that 90,000 miles on it.

Jeff,

Lets just yank the tranny and put in a new clutch, then we can fix the brakes and voila! Back on the trail.

Jase and Stace said

Jeff_R said

Now it sounds like my throw out bearing is shot. There is a loud, high pitched squeal when I press in my clutch pedal. I made an appointment with my local mechanic but he can't get me in until September 11th. Looks like I will need a new clutch, etc. I'm hoping I will get it back on the 14th to be able to make the Barrett Lake run but I might have to miss that run. I still need to figure out what to do about my brakes. Looks like my TJ is staring to show its age but it still has less that 90,000 miles on it.

Jeff,

Lets just yank the tranny and put in a new clutch, then we can fix the brakes and voila! Back on the trail.

😀

Wow, that sounds great Jason (Dozer!). It's beyond my pay grade but I will be glad to assist in any way I can if you know how to do it. I have a RE 4.5 long arm lift with the RE skid plate/crossmember and an Atlas T-case. I really want to make the Barrett Lake run so if we can get it done before then, that would be fantastic because I doubt that the shop can get it done by then.

Jase and Stace said

Jeff,

Lets just yank the tranny and put in a new clutch, then we can fix the brakes and voila! Back on the trail.

😀

Hey Jeff,

Clutch is not very hard to do as I did mine myself. (Just heavy) I replaced the clutch in my TJ a few years ago.  I have a transmission jack and the 3 foot 1/2" socket extension to get the top bolt on the bell housing. I went with the Heavy duty LuK clutch and I also replaced the Fly Wheel while I was in there. I also have the Fly Wheel holder so it doesn't spin when tightening bolts.  If you get a new flywheel be sure to buy new bolts (ARP Pro Series Flywheel Bolts).  I bought everything from Summit Racing.

I need you at Barrett so you can spot me through!

I got you Greg.... BTW, you don't mind body damage right 😇

Gregulator said I need you at Barrett so you can spot me through!

Sloguy said Hey Jeff,

Clutch is not very hard to do as I did mine myself. (Just heavy) I replaced the clutch in my TJ a few years ago.  I have a transmission jack and the 3 foot 1/2" socket extension to get the top bolt on the bell housing. I went with the Heavy duty LuK clutch and I also replaced the Fly Wheel while I was in there. I also have the Fly Wheel holder so it doesn't spin when tightening bolts.  If you get a new flywheel be sure to buy new bolts (ARP Pro Series Flywheel Bolts).  I bought everything from Summit Racing.

I see a couple LuK clutch kits on Summit Racing for the 4.0L engine. None say heavy duty and I'm not sure what one I should get. If I do this, I will need some help making sure I order the correct parts. I understand it's a good idea to replace the fly wheel at the same time. What else should I replace?

Jeff_R said

I see a couple LuK clutch kits on Summit Racing for the 4.0L engine. None say heavy duty and I'm not sure what one I should get. If I do this, I will need some help making sure I order the correct parts. I understand it's a good idea to replace the fly wheel at the same time. What else should I replace?

The Throw Out Bearing and the Pinion Bearing.  I don't know if they are part of the kit. What year is your Jeep again? 2004?

Yes, it's an 04.