Well been gone for a while again but one thing I have done while absent is finally get my new version of rear disc brakes completed. Here is version 1.0
https://www.ford-trucks.com/forums/6...-are-here.html

Version 2.0 uses the same rotors but uses 99-04 rear calipers, hoses, pads and mounting. It is not a project for those who don't know how to use a torch very well and you need to be able weld good too. Since the calipers mount to a bracket that bolts to the flange on the rear axle tube you have to cut the axle tube flange off with a torch and weld a newly fabricated flange to the axle tube that matches the superduty mounting bracket. The flange was much easier to fabricate than the mounting for the Chevy caliper on version 1.0. I simply made a cardboard template to find the center of the axle tube hole and used a 3 inch hole saw to make the large hole for the axle tube to fit though.

Sorry I don't have any pictures since I deleted them off my phone on accident. But I will get some that show the final project. I have been running them for over 2 months now and they work great. My main objective to the swap was to be able to use the Super duty parking brakes. Well it won't work! The hubs are too close to the mounting flange on the OBS axle so there is not room for the parking brake shoes to fit in there. Not a big deal to me as I don't have vehicle inspections and in Michigan parking brake cables last only until the first salt is spread on the roads in the winter.

Now to compare 1.0 to 2.0
Pro's of 2.0 over 1.0
-all ford parts
-the brake pads fit the rotor correctly without any dorking around
-easier to fab if you have torch and welding skills or know someone who does
-much better quality brake pads available over the old Chevy pads
-pads are a little bigger so even though I couldn't feel a difference I bet it stops a little better

Con's of 2.0 over 1.0
-Cost more for parts unless you use caddy parking brake calipers for the 1.0 install
-still no parking brake option
-super duty caliper slides have issues over time of seizing up and needing to be freed up
-No ability to go back to stock drum brakes if ever wanted to(ie selling the truck)


Over all I am glad I did the swap. My 1.0 brakes were needing new pads for the second time in about 40K so I was not getting good life out of them. I expect better pad life from the SD pads with this set up. Bummed still about the parking brake but there are other options just a lot more work if you need them.

Ask questions and I will work on getting some finished product pictures that will help you get the picture of what I had to do with the axle tube. BTW cutting off the stock flange was a gut check moment where I really hoped I could make this all work!! YIKES!! No other way but to chop it off and see what I could make work!

 

I may look into doing this this winter. I'm going to pull the drums apart and see what things look like. I know where there are a bunch of SD trucks to get parts from. I'll print this thread up later on when you get some pics up. Welding and torch work not a problem, parking brake I kinda wish I had. The only time I use it is when I load our 22k forklift on the trailer, I put it in N, set the brake and block the tires.

If the parking brake won't work, I may not be able to do the swap. I wasn't thinking about that when I started typing...

 

Just did a little more reading here
fordmann.com | F-350: Sterling Rear Disc Conversion
They did the same thing just in a longer about way. They show that you can clearance the parking brake shoes and make them fit. The only difference is that they used van brakes rather than truck brakes. Not sure how much difference it makes. Perhaps I will look into it soon.

 

the e series super duty dualys have disk brakes and our lug pattern, im pretty sure they are chassis cab with, I'm pretty sure on a srw application you could just move the spring mounts and be done with it

 

Cab Chassis axles are usually shorter than SRW axles. Not sure about standard dually axles on length. Also not sure when the change was but the vans used a Dana 60 rear axle rather than a Sterling

 

your probably right, we have a early e-superduty cube van at work, if i get a chance i might try taking some measurements off the rear axel

 

I need rear disks, but need the Parking brake too.
Damn hand rattlers.

 

Tim,again thanks for the info...the fab-work is not a problem as I have the skill-set to perform the transplant,..ie..welding,Plazma torch and all the other equipment. I also use the parking brake for loading my trailer with a bobcat and other jewells I happen on to. I will gather all the parts and get to one of these..still have not decided....But again thanks..Patrick