I figured I do a little write up for you guys if any of you are interested in putting rear disc brakes on your 3/4 or 1 tons. I wasn't planning on do it but every once in a while you get a curve ball.

It started when I got a great deal ($22 ea) on new take off hub centric 16" dually rims. My 69 dana 70 was set up for lug centric wheels so I just needed to find some 87-98 E-350 hubs. With no luck at local wreckers I managed to find some at a wrecker two provinces over in British Columbia. Imagine my surprise when I opened the box and found I got two E-Superduty DRW disc brake hubs.

So the search was on to make everything work as my drum setup was useless at this point. Now for the tech! I've tried to make it as complete and comprehensible as I can.

Here are the possible donors:

1999-2007 E250/350
- No pics for this one
- Econolines were only equipped with a partial dust shield and were later superseded to the F-250/350 full shield with a TSB.
- Used the same bracket for both sides and casting number on bracket is 13032401.
- Superseded parts:
1C2Z-2390-AB = DRW before 11/29/2004 (F-250/350 style)
1C2Z-2390-BA = SRW before 11/29/2004 (F-250/350 style)
5C2Z-2390-AA = DRW after 11/29/2004 (uses different park brake shoes)
5C2Z-2390-BA = SRW after 11/29/2004 (uses different park brake shoes)
- 12.84" Rotors with 8x6.5" bolt pattern
- Should work with most 16" wheels.

1999-2004 F-250/350



- Full dust shield
- SRW used two different brackets. 13032401 and 136164. The left caliper is mounted in front of the axle and right caliper is behind axle. Picture above shows different park brake cable mount.
- DRW used the same for both sides. 13032401
- 12.84" Rotors with non desirable bolt pattern 8x170mm.

2008-2013 E-250/350

- Full dust shield
- 13.58" Rotors with 8x6.5" bolt pattern. May be hard to match rotor size for the front.
- Limited selection of 16" wheels and may need 17"+.

2005-2010 F-250/350


- Full dust shield
- 13.38" Rotors with non desirable bolt pattern 8x170mm. May be hard to match rotor size for the front.
- Limited selection of 16" wheels and may need 17"+.

2001-2005 Dodge 2500/3500



- Full dust shield
- Used the same bracket for both sides and casting number on bracket is 13032401.
- 13.85" Rotors with 8x6.5" bolt pattern. May be hard to match rotor size for the front.

The ideal setup is using 1999-2007 E-250/350 rotors with brackets from the E-250/350, F-250/350 or Dodge 2500/3500 and then Ford calipers. Econolines uses different calipers than the pickups but they interchange. They use the same park brake shoes except 2004-07 E-250/350. Park brake hardware for the F-250/350 is best to use as it is a complete kit.

I really recommend only doing this swap on Dana 60/70 rear axles. IMO the Timken axles aren't worth it. If your going the DRW route like me then your going to need a 1968 or newer Dana 70 as all the spindles are the same.

SRW trucks will just reuse their existing hubs. The Econoline rotors will clear hubs with an 8" outer diameter and 4.85" inner diameter.


Here is a link to a diagram Fordmann has on his website to make the required flanges to weld onto your rear axle. The center hole will depend on your choice of rear axle.
http://www.fordmann.com/D70_Flange_Final.pdf

The local big wrecker wouldn't sell me the caliper brackets separate from the axle so I bought them from Ford. Use the part numbers above if you can't find a wrecked axle other wise they only list complete assembly's with park brake shoes at double the cost.



I managed to find a F-250 at a pick a part wrecker surprisingly as they don't pay enough to get the bigger newer stuff. So I grabbed all the nuts/hardware/calipers as that all adds $$ from the dealer. If your donor has bent/destroyed dust shields, Dorman makes replacement ones for the F-250/350s.

Here are the 1999-2004 F-250/350 calipers:



As for the e-brake cables here are some pics of the typical stock setup:


I plan on just using two of the same cable and have it setup like the factory on our trucks with a single cable to the lever.

Just for fun:


I'll have more when I get the brackets finished and welded to my axle.

 

Nothing I am needing, but a nice write-up for those in your situation. Thanks.

 

Now if they just made a setup that plugged into the F500/600s.
Excellent post, bump!

 

Here's an update:
First you'll need to remove the original backing plate flange

Slide your new flange on and then bolt up your hub/rotor. Then clamp two pieces of 3/16 flat bar to the rotor face. Now clamp your new flange at the right angle.

Now spot weld it and check fitment with the park brake assembly and caliper before welding it solid.

Volia! You now have rear disc brakes.