• ronman
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Topic: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

Cousin is a rural route carrier for the USPS and was given a basketcase '83 DJ-5M by her retiring coworker. Naturally, I've been asked to whip it into shape.
I drove it last night and it's hands-down the worst vehicle I've ever had the misfortune of driving.
The biggest part of that is the braking: there's about 4" of pedal travel, but the only actual braking happens in the last (seriously) like 1/4". It's an incredibly fine line between modulation and lockup, and makes it for the most part, undrivable.

So I got it in my head that it really needs to be converted to front discs with power assist. I've found a couple of poorly-written "articles" scattered about that talk about CJ5 disc conversion, but nothing particularly specific for the DJ.
Compounding the problem is the fact that I don't know what the front axle is. I took a few pics of it, so hopefully one of you geniuses can help me ID it...

http://www.ronman.org/pics/misc/jeep/IMG_8632.jpg
http://www.ronman.org/pics/misc/jeep/IMG_8633.jpg
http://www.ronman.org/pics/misc/jeep/IMG_8634.jpg
http://www.ronman.org/pics/misc/jeep/IMG_8635.jpg
http://www.ronman.org/pics/misc/jeep/IMG_8636.jpg
http://www.ronman.org/pics/misc/jeep/IMG_8637.jpg
http://www.ronman.org/pics/misc/jeep/IMG_8638.jpg
http://www.ronman.org/pics/misc/jeep/IMG_8641.jpg

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

Those are giant brakes.  Let them live!!!

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  • ronman
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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

They're like 11x1.5"... the wide angle lens makes them look much bigger than they actually are.

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  • From: WPB Fl.
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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

There was one @ the local JY, prob gone by now but someone had disk on the front, a semi finished interior w/speakers and a hang on a/c unit, I stopped to marvel but knowing nothing of postal jeeps there were no notes I can share.

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

Do you know which yard by any chance?

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

It was + 3 months ago and those guys deal in volume but no harm giving a call.

One block from my shop, You pull and Pay, Benoist farms road

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Sebring Chump 6th again -NOLA Chump 1st -PBIR Chump Transmission 16th
Daytona 11th - Sebring 6th - Atlanta Motor Speedway 2nd - Road Atlanta Trans Fail 61st
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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

Thanks Ed. cool

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

BTW you coming up to do the Chump race at Daytona next month?

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

Damn right, Wait  we got a month and the cars in 1000 pices...

Whats your plans that weekend?

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

I'm gonna be there hanging out with Hong Norrth guys. Probably bring the camper out...

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

Those guys are fast!, Dont be shy, stop by, I am not driving first stint.

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Sebring Chump 6th again -NOLA Chump 1st -PBIR Chump Transmission 16th
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  • From: Van Nuys, CA
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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

How about swapping the whole front axle from a 80s Jeep Cherokee 2wd? They weren't  leaf sprung, but is all else is right you would just have to weld up spring perches. I'm sure PettyCash will chime in here eventually and give you a definitive answer.

11" x 1.5" brakes should be fine for a vehicle that is most likely about 200olbs. Sound to me like the master cylinder is bad or the system is full of old fluid and air. My 1960 Chevy weighs 4000lbs and has 11" drums all the way around and its okay. Well, its okay for 1 stop, then its best to les it cool off.

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

My first thought was also a '84-'01 2WD Cherokee beam axle and associated brake components, but they might be on the wide side.  It wouldn't be a terrifying amount of fab work, but it wouldn't be a straight forward swap either.  I'm betting there's something wrong with the current braking system, which would probably be easier to find and fix than doing the whole axle swap.

A compromise might be finding CJ-5/7 front knuckles with discs and seeing if they fit the inner-Cs, but I honestly have no idea.  Anybody I know who has screwed around with DJs have done full 4WD drivetrain swaps.  If you're really serious about doing this, I can point you in the direction of the people who would know the answer.

www.georgethejeep.com

Call them and ask for George or Diana, they will know the answer and have the parts to make it possible.  Tell 'em I sent you.

-Matt

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  • From: WPB Fl.
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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

A bit of recall on the disk jeep at the JY, there was a unadulterated similar unit next to it and if memory is correct I did not see anything more then bolt on stock stuff was needed to make the conversion.

Homestead Chump 5th-Sebring Chump 6th-PBIR LeMons 9th - Charlotte Chump  Crash-n-Burn 9th
Sebring Chump 6th again -NOLA Chump 1st -PBIR Chump Transmission 16th
Daytona 11th - Sebring 6th - Atlanta Motor Speedway 2nd - Road Atlanta Trans Fail 61st
Road Atlanta 5th - Daytona 13th

15 Reply by ronman (edited by ronman 2012-04-21 09:32 PM)

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

I've looked into the CJ and XJ parts, but there's a serious dearth of info on these things. Other problem is that caliper brackets are hard to come by.
Next weekend I'm just gonna replace all the shoes and hoses, rebuild the cylinders and see what else I can find wrong.

Ed, I called the yard and they said they haven't had it for about a month. sad

Later on I'll see if I can find an XJ front for the right price, or who knows, maybe I'll learn to, you know, actually fabricate, and stick a Mustang II setup in there.

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

ronman wrote:

BTW you coming up to do the Chump race at Daytona next month?


Wait, you had me going there, that race is the end of August !

Homestead Chump 5th-Sebring Chump 6th-PBIR LeMons 9th - Charlotte Chump  Crash-n-Burn 9th
Sebring Chump 6th again -NOLA Chump 1st -PBIR Chump Transmission 16th
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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

Negative!

May 27
DAYTONA INTERNATIONAL SPEEDWAY: 14 Hour
"The 14 Hours of Daytuna"

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

Well this being the case I should pay more attention and pick up all the pieces to reassemble really quick!

Homestead Chump 5th-Sebring Chump 6th-PBIR LeMons 9th - Charlotte Chump  Crash-n-Burn 9th
Sebring Chump 6th again -NOLA Chump 1st -PBIR Chump Transmission 16th
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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

Only a month to prep, what could possibly go wrong?

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

All we need is headlights, fenders, order 4 brakes,upgrade master, order tires, find wheels to fit tires, fix bushing,align, finish putting in the rest of left out trans bolts, flush trans, change oil, get a lack of help for  good measure etc

Homestead Chump 5th-Sebring Chump 6th-PBIR LeMons 9th - Charlotte Chump  Crash-n-Burn 9th
Sebring Chump 6th again -NOLA Chump 1st -PBIR Chump Transmission 16th
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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

If it wasn't a 400 mile round trip I'd come down and help you whip it into shape...

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

I appreciate the thought  the really hard part is going to be next months credit card bill.

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Sebring Chump 6th again -NOLA Chump 1st -PBIR Chump Transmission 16th
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  • From: SSF & Burlingame
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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

Believe it or not, I have a friend who's son has one of these.  I will try & get you some info......

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

I would greatly appreciate it, Mike!

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25 Reply by MikeZilla (edited by MikeZilla 2012-04-26 10:48 AM)

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Re: Anybody ever convert a Jeep DJ (mail truck) to disc brakes?

Just spoke with him. They had stabilized the front leaf spring perches but unfortunately  had not converted to disc brakes. I did mount disc brakes on a 48 Nash by using 70's Chevy 4X4 backing plate/caliper mounts with calipers. These are heavy stamped steel plates which are easily modified. Then I used chevelle rotors. I believe the 70's/80's Cadillac Sevilles used a similar but smaller bracket on the rear.

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