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Disc brake conversion

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Offline Catalystracing

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Disc brake conversion
« on: April 09, 2019, 02:12:37 PM »
I completed this little project the other day, so well worth it.
Conversion kit from zookparts.com
Galant rear calipers
Vitara front rotors.
The kit is purely bolt on, using the zook hand brake cables, no cutting welding etc required.
Took about 3 hrs for the first side and about 45 mins for the 2nd  ;D
92 Vitara 16GA SWB EFI Auto 4x4 Manual hubs
Rear Lokka, front steel diff with short CV mod
2" spring lift, top hat flip
Stage 2 cam.
Disc brake conversion.

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Offline beagle..t

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Re: Disc brake conversion
« Reply #1 on: April 13, 2019, 11:28:15 AM »
what yr did you do it on and what was the price of the kit website is in chinese
new rig aka "the mule" 2002 tracker
V6 swap auto  ,2 dr ,2" BL,2" jeffs kit 512 gears warn hubs and 30/9.5/15 BFG AT

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Offline Catalystracing

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Re: Disc brake conversion
« Reply #2 on: April 26, 2019, 10:05:04 AM »
Hi,
Details of truck are in my signature.
Website should be https://www.zukparts.com/Suzuki-Vitara/Suzuki-Vitara-rear-disc-brake-conversion-early-axle

Cheers,
Paul.
92 Vitara 16GA SWB EFI Auto 4x4 Manual hubs
Rear Lokka, front steel diff with short CV mod
2" spring lift, top hat flip
Stage 2 cam.
Disc brake conversion.

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Offline olija

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Re: Disc brake conversion
« Reply #3 on: May 21, 2019, 10:27:26 PM »
I noticed they have a kit for "later" model Vitaras as well. I wonder how hard it would be/ how worthwhile it would be to do this on an XL7?
97 Sidekick 4door 5 speed, 1.5 spacer lift, 2" body lift, CJ rims, locked rear, 31's, 4:1 low <SOLD>
01 Vitara 2.0L 5 speed, 2.5" Calmini lift, 2" body lift, Sidekick rims, locked rear, 31's, 4:1 low, 5.13 diffs <SOLD>
03 XL7 2.7 5 speed, 4.5" AE lift with OME springs, 2" AE body lift, 5.13 diffs, 3:1 low, 235/80R17 BFG AT's on Ultra 17x8 with 1" spacers, skid plates, Balmer Fab front bumper

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Online fordem

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Re: Disc brake conversion
« Reply #4 on: May 22, 2019, 02:20:18 PM »
I take it you're aware that the XL-7s use a different rear axle - having said that, I've not looked at the brake hardware to see how different it is.

Whether or not it's worthwhile is going to be something of a personal evaluation - the benefit will be determined by your usage - if you're not frequently in sloppy goopy mud, I see no reason to do it.  The mud gets into the drums and creates an extreme wear scenario.
'98 SQ420 Grand Vitara
'05 JB420 Grand Vitara
'16 APK416 Vitara
'21 A6G415 Jimny

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Offline olija

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Re: Disc brake conversion
« Reply #5 on: June 28, 2019, 09:55:08 PM »
Yes, I know the XL7 uses a different rear axle; that's why I wondered how hard it would be to make it work, because it still uses the same 4-bolt flange on the end of the axle housing that holds the wheel bearing and axleshaft on.

I would also debate your point on discs being superior to drums in nasty mud. As a mechanic in northern Canada I see, almost exclusively, most on and off-road semi trucks are all still running air drum brakes even though good air disc brakes have been available for over a decade; in addition, many pickup truck manufacturers are switching back to rear drum brakes on many of their models, especially work trucks that see lots of muddy gravel roads specifically because disc brake pads get eaten up very quickly due to the self-cleaning design of disc brakes. Even in nasty mud, drums do a pretty good job of keeping muck out compared the the open concept of a rotor. BUT, and this is a big BUT: I will concede that once the drum does get full of mud inside then you will have a problem
97 Sidekick 4door 5 speed, 1.5 spacer lift, 2" body lift, CJ rims, locked rear, 31's, 4:1 low <SOLD>
01 Vitara 2.0L 5 speed, 2.5" Calmini lift, 2" body lift, Sidekick rims, locked rear, 31's, 4:1 low, 5.13 diffs <SOLD>
03 XL7 2.7 5 speed, 4.5" AE lift with OME springs, 2" AE body lift, 5.13 diffs, 3:1 low, 235/80R17 BFG AT's on Ultra 17x8 with 1" spacers, skid plates, Balmer Fab front bumper

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Offline JollyZuk

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Re: Disc brake conversion
« Reply #6 on: September 16, 2019, 03:19:22 AM »
Olijah, how are the brakes on you XL7 with the oversized tires?  I am not super impressed with the braking on my Kick with just 235/75 tires, and I really want that sorted if I ever go bigger.  Didn’t know though if the XL7 had sufficient brakes for oversized tires.
1995 Sidekick JLX
16v 5 spd, milled head, LROR Stage 2 clutch
2" Spacer lift, XL7 rear springs,  2nd Gen front springs, W-Body GM Struts on front
OEM ROOF RACK!!!

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Offline olija

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Re: Disc brake conversion
« Reply #7 on: September 21, 2019, 10:20:46 PM »
It does the job...I've had the vehicle for 3 years and put over 35,000km on it and haven't had to change the front or rear brakes yet, and that's with a fair bit of driving around with camping loads, house reno loads, passengers, etc.  It is a manual tranny so it slows itself down pretty good as soon as you let off the gas, compared to an auto which just coasts for all eternity. I sometimes dream about building a Ford 9" rear axle to swap into this thing, but so far it's holding up to my driving just fine...I just wish I could have a locker, and some bigger brakes wouldn't hurt either...maybe a Lincoln locker and a disc conversion like this would accomplish most of my goals?
97 Sidekick 4door 5 speed, 1.5 spacer lift, 2" body lift, CJ rims, locked rear, 31's, 4:1 low <SOLD>
01 Vitara 2.0L 5 speed, 2.5" Calmini lift, 2" body lift, Sidekick rims, locked rear, 31's, 4:1 low, 5.13 diffs <SOLD>
03 XL7 2.7 5 speed, 4.5" AE lift with OME springs, 2" AE body lift, 5.13 diffs, 3:1 low, 235/80R17 BFG AT's on Ultra 17x8 with 1" spacers, skid plates, Balmer Fab front bumper

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Offline Drone637

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Re: Disc brake conversion
« Reply #8 on: September 23, 2019, 10:48:06 AM »
Olijah, how are the brakes on you XL7 with the oversized tires?  I am not super impressed with the braking on my Kick with just 235/75 tires, and I really want that sorted if I ever go bigger.  Didn’t know though if the XL7 had sufficient brakes for oversized tires.

Do you have a 4-door or a 2-door?  If it's a 2-door get a set of rotors, pads and calipers from a 4-door.  Bit bigger and vented rotors and they bolt right up.  You can swap on the rear drums as well, but it's a bit more work.
96 Geo Tracker, x-SJ-410,  x-White Rabbit, x-Project Trouble
Crawlers NorthWest
x-Trouble Racing

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Offline JollyZuk

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Re: Disc brake conversion
« Reply #9 on: September 23, 2019, 09:01:36 PM »
Mine is a 4 dr.  I have a parts XL7 and am wondering what it would take to use the front rotors and calipers from the XL7, since they are slightly larger.  I am considering swapping in the XL7 rear end as well, so that would increase the size of the rear brakes...but make a disc brake conversion more difficult.
1995 Sidekick JLX
16v 5 spd, milled head, LROR Stage 2 clutch
2" Spacer lift, XL7 rear springs,  2nd Gen front springs, W-Body GM Struts on front
OEM ROOF RACK!!!

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Online fordem

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Re: Disc brake conversion
« Reply #10 on: September 24, 2019, 06:18:18 AM »
Please note - you'll need 16" rims to clear the XL-7 brakes.
'98 SQ420 Grand Vitara
'05 JB420 Grand Vitara
'16 APK416 Vitara
'21 A6G415 Jimny

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Offline Drone637

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Re: Disc brake conversion
« Reply #11 on: September 24, 2019, 03:15:45 PM »
Please note - you'll need 16" rims to clear the XL-7 brakes.

But you can put the XL-7 hubs on the Tracker front end?  That's pretty fun.
96 Geo Tracker, x-SJ-410,  x-White Rabbit, x-Project Trouble
Crawlers NorthWest
x-Trouble Racing

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Online fordem

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Re: Disc brake conversion
« Reply #12 on: September 25, 2019, 06:16:45 AM »
I believe the entire spindle/knuckle assembly should be a bolt up swap - not certain what impact it would have on the steering/suspension geometry.
'98 SQ420 Grand Vitara
'05 JB420 Grand Vitara
'16 APK416 Vitara
'21 A6G415 Jimny

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Offline JollyZuk

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Re: Disc brake conversion
« Reply #13 on: September 25, 2019, 11:32:24 AM »
I am not sure about it bolting  up or not, but I figure since I have the one arts rig I may as well check it out.  What would be ideal is if the XL7 caliper bracket would bolt up to the sidekick spindle, and all that would need to be swapped is the caliper, bracket and rotor.
1995 Sidekick JLX
16v 5 spd, milled head, LROR Stage 2 clutch
2" Spacer lift, XL7 rear springs,  2nd Gen front springs, W-Body GM Struts on front
OEM ROOF RACK!!!