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Front Disc Brake Installation
 I have had a few people ask about Front Disc Brakes for their Baja's and how to in stall them. Here is how I did it. Good luck and happy Stopping!
This is the kit I used to put Disc Brakes on the 1963 link pin front beam in my Baja. The Kit includes Rotors/Discs, Calipers, Brake Pads, Caliper Brackets, Bearings and Seals. Things I added to the installation are Braided Steel Brake Lines, 4 Bolt to 5 Bolt Wheel Adapters, Wheel Studs, and Chrome Lug nuts. Things that you will need to get are 4 bolt 3/8" Wheel Spacers, and Dust Covers/Caps. Supplies you will need are Wheel Bearing Grease, Brake Cleaning Fluid, Loc Tight, Dot-3 Brake Fluid, Paper Towels, Jack and Jack Stands, and a good set of metric tools.
We have the Baja on jack stands and ready for the Front Disc Brake installation.
We have removed the old dust cover at this time. Do not forget that the driver side wheel-bearing nut turns clock wise to remove it. Some of you might still have the 2 lock nuts with the steal tabs that keep them locked in place. Pry the tabs back and remove the nuts.
We have removed the old drum at this point. You might run across a few problems removing it, if so try this. Back the brake adjusters up a few clicks. The inner wheel bearing will be a little snug on the shaft so a little work with a pry bar will pop the drum off. This is also a good time to remove the brake line from the old slave cylinder on the backing plate.
It only takes 3 bolts to remove the old backing plate. After you get the backing plate of you will be ready to start the install of the new disc brake kit. This is also a good time to look over all your front-end parts. Tie rod ends, Ball joints or link and king pins. Get the grease gun out and make sure your link pin front end is greased too.
Here we start to install the caliper bracket in the same place as the old backing plate. Make sure you don't put this on up side down. NOTE: You must see the 2 welded on nuts on your side of the caliper bracket.
Pack your new wheel bearings with High Temp Wheel Bearing Grease. The best way is to place a ball of grease in your hand and roll the bearing in it. Make sure your bearing is fully greased before you install it.
After you place the greased wheel bearing in its race. NOTE: This kit had the Wheel Bearing Races already installed in the Disc, you might have to install the race with your kit. You need to install the new seal. The best way to do this is find some flat metal object that covers the whole seal and tap it in with a hammer.
I would also look into getting a clamp type wheel-bearing nut at this time. I think it works better than the 2 locking nuts used in stock form. Place your disc on the spindle. Install the outer wheel bearing and the wheel nut. Don't forget that the wheel nut on the driver side will tighten in a counter clockwise direction. Do not over tighten the wheel-bearing nut. You do not want to trash your new bearings the first few days you have them on your car. Just snug them up so you do not have any slop or play and the disc still spins free.
At this point install your disc brake caliper. Make sure that the caliper is centered and will not hit your new disc. Install or reconnect your brake lines. It would be a good idea to put new brake lines on at this time.
Install the studs for your lug nuts now. Use some Loc Tight on the stud threads. You do nut want the studs to back out when you remove your wheels.
Install the 3/8" spacer plate now. The caliper will hit some wheels and 4 to 5 bolt wheel adapters.
Install the 4 to 5 bolt wheel adapters at this time. You can see why the 3/8" spacer plate is needed at this time. The clearance is about 1/8" from the caliper to the wheel adapter.
Install the dust caps. The dust cap on the driver side should have a hole in it for your Speedo cable, if not your Speedo cable has no place to go. Install the C-clip for the Speedo cable. You need to bleed your brakes at this time and should adjust your rear brakes.
All that's left is to install the front tires. Set your car back on its feet and give it a few test stops out in your driveway. Look for any brake fluid leaks. At this point you should be done and ready for some real stopping power. NOTE: The front wheels get spaced out about 2" with this kit.
I can't believe how well this little project worked. We had the car done in about 1 1/2 hours. The car stops straight and pedal feel is great. I don't have to deal with adjusting front brakes any more and getting water on the brakes should not be a problem. If you're putting a hot engine in your car you should plan on a way to stop it. This Drum to Disc brake swap should do the job for you.
Last Update: March 8 1998
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