1993 Dodge w 250 diesel "EGR" rear disk brake conversion

Tire and axles removed

Next i removed the brakes and backing platesi

Next step remove drums from hubs, this was alot easier than i thought it would be

Next step install new rotors using old original wheel studs,i also installed new races, bearings, and seals

Test fitting the rotor assembly and adapters

New brackets bolted in place, i had to use 2 spacers on each side

The only problem i ran into,was the banjo bolt hit the inner addapter and i had to grind a notch for it to clear

The left side together `and ready for the brake lines and e brake cables

OUCH!!! While grinding the right bracket the cut of saw bit me, i could'nt get the bleeding to stop so of to the hospital i went, cut the nerve, and the main vesel

feeding the end of my finget , 4 stiches later a`nd i'm home , i''m goin  to try to finish tomorrow and i post the rest of the pics, and a report when tested

This page was last updated on: May 16, 2004

Sunday i was able to finish installing the  left rear disk and caliper and plan out my e brake cables and brake lines, the following pics are from monday installing brake lines and cables

These are the extension tubes that come with the kit to extend the e brake housing because of the diferent

lenths needed with the new calipers, but they did'nt work real well with the location i chose to place my calipers.

so i removed the spring covering the cable end and mounted the factory end up to the stop on the caliper

and pulled the slack back under the truck and clamped

This is how my E brake cables look when finished and adjusted

I tried everything to make something that looked half decent out of the old brake lines but with no luck, and a good thing, when i got ready to install the new center brake line i could not get the lines lose, so i bought some new 3/16" line and mad a new set of lines for the rear (this requires a 45 deg double flare tool to make the ends)

This is the completed line set and routing, i removed the protective springs from the original lines and slid them over the new set, you can also see the new center line going up to the frame

While i was at it i installed all three new  lines on the front

New center line on the front

This is the clearance in the rear with a 16" rim and tire, about a inch to spare, i don't know why this would be aproblem with a dually, unless it's a hub thing (wrong studs)

A better view of the rear end completed

Nothing left but bleeding and testing, but i've been apointed BBQ master so it will have to wait to tommorow