Bolt-On Disc Brake Conversion Kit on a 1992 Toyota Truck - Compact Discs

11.Also included with the kit is a complete replacement set of stainless steel-braided brake lines. These will bolt right into the unions on the rearend and on the new calipers. They look trick, too.

12.To continue, we replaced the axle bearings (you may want to replace yours at this point) and axle race, along with the retainer ring we previously had removed, and slid the axle sans drum brakes back into the rearend, securing it using the factory nuts we had removed. We installed the aluminum hub-centric ring appropriate for the Toyota reend before proceeding.

13.In the kit, you'll find a pair of H-shaped brackets. These are bolted to the rearend at the axle tube ends using spacers and will serve as the permanent mounts for the disc brake calipers.

15.Simply slide the new brake rotor over the lug studs as shown. We secured the rotor temporarily with a couple of lug nuts to keep it from moving around.

16.&17.Next, set the new brake caliper into place and bolt it to the caliper mount as shown.

18.When the caliper bolts are tightened, the assembly looks like any other factory-installed disc brake system.

19.After the process was completed on the other side of the truck, we began to install the new emergency brake cable system.

20.This was the hardest part of the installation because there's more than one way to install the cables and make them work. After some trial and error, we found ways to route the cables and get enough tension on them to engage the rear brakes from the cab of the truck.

21.To make the rear disc brakes work, there has to be a whole lot more pressure in the brake lines than drum brakes require. To pump up the pressure, the pin behind the master cylinder has to be extended, and a proportioning valve must be added.

22.Installation of the proportioning valve was easy, especially since Downey Off-Road had included everything we needed to install it, except a tubing cutter to remove about 2 inches of brake line to install the proportioning valve.

23.Completed, the new rear disc brake setup needed to be pressure-bled to maintain high pressure within the system, allowing for stopping capabilities that can't be matched by a stock braking setup.