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• View topic - The 1st Jimny Disc Kit Write Up!

The 1st Jimny Disc Kit Write Up!

The 1st Jimny Disc Kit Write Up!

Postby muddyzook » Tue Mar 09, 2010 12:13 pm

A massive massive thank you goes to Andyw4x4 for his help in this and providing most of the photos you are about to see!

OK to start off with your going to need the following

1 Suzuki Jimny without ABS... THIS KIT WILL NOT FIT IF YOU HAVE ABS!!!!!!
2 SJ/Jimny/Vitara non vented discs
Pair of Rover 400/200/45/25 rear brake calipers with pads and flexible pipes
2 Rover handbrake inner cable clevis pins
2 Rover handbrake outer cable retaining clips
Brake hydraulic pipe and fittings as required

and of course the muddyzook.com Jimny Rear Disc Conversion Kit which includes the following

2 Disc spacers
L&R Caliper brackets
2 Handbrake cable inner adaptors
2 Handbrake cable outer adaptors
2 Bearing retainers
2 Split pins
8 M8 nyloc nuts
4 M10x1.25 high tensile bolts
8 M8 high tensile bolts

Your going to need to remove your rear wheel bearings to do this, so you my want to consider doing at the same time they need replacing!

I'm not going to write out the complete fitting instructions here but you will get the general idea after you have finished reading it.

Take of the complete rear brakes as they stand today, yet the lot.... drum, back plate, wheel cylinder the lot, just leave your self with the pipe work for the time being.

Take the bearing and back plate off your half shaft and replace it with the bearing retainer, put the bearing retainer on the half shaft with the centre hole chamfer away from the wheel flange.

Put the calliper mount on the end of the axle

Image

and then refit your half shaft

Image

Secure the bearing retainer using the supplied M8 bolts

Image

Now place a disc spacer on the axle flange

Image

and then put a disk on, sticking a couple of wheel nuts on to hold it in place will make your life a little easier

Image

Put the 2 supplied grub screws in the M8 holes in the disc to centralize the disc

Bolt the calliper mounting bracket onto the hanging bracket using the new bolts provided, and some locktite!

Image

pop a couple of pads in

Image

and then put the calliper

Image

Do everything up tight! and check that the calliper clears the disc, there are manufacturing variations in the caliper, which may require easing with a file or careful use of an angle grinder.

and the bit your all doing this for to get a hand brake!!!!!

Slide the Handbrake outer cable adapter over the cable

Image

push the adapter through the hole on the calliper and secure with the clip taken from the Rover, pic shows calliper off the car but you get the idea.

Image

fit the inner cable adaptor (it may be necessary to strip some of the plastic coating off the inner cable)

Can't find a photo of this bit :-( maybe andy will take one if we ask him nicely!

Put the forked inner cable adaptor end over the handbrake quadrant on the caliper. Fit the clevis pin and secure with the split pin supplied. The clevis pin usually has a groove across its head, note the orientation of this relative to the split pin hole to aid alignment for fitting the split pin.


Image

Image

Image

OK all thats left to do is hook up the hydraulics, not going to tell you how to do this as there is no hard and fast rule, but your going to need a T piece and some new pipe work making up, work through it slowly and make sure there are no leeks! bleed them up and away you go!

Well boys and girls thats how to fit it, there are a couple of other things you need to know.......

This is what you get when you order a kit

Image

They cost £ 154.00 + P&P unless you can collect from us, they are now in the

IMPORTANT

Unless you are running the standard Jimny steel wheels, you will need to replace you studs with at least 5mm longer ones, we are now stocking these in the muddyzook store.
muddyzook
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Re: The 1st Jimny Disc Kit Write Up!

Postby stonecriss » Mon Dec 13, 2010 9:37 am

Hi Guys

Trying to read thei psot and there's no pictures
anything i am doing wrong?? :oops:
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Re: The 1st Jimny Disc Kit Write Up!

Postby dunk » Mon Dec 13, 2010 8:02 pm

Hi Chris we do no that there is a fault with this post, we are just waitning for UM to sort it out. The kit is really easy to fit if you get any problems just shout ;)
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Re: The 1st Jimny Disc Kit Write Up!

Postby muddyzook » Tue Dec 14, 2010 11:49 am

OK we have lost the directory off the server that contains the images for this post :roll:

I will restore it later tongiht for you sorry guys :hug:
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Re: The 1st Jimny Disc Kit Write Up!

Postby uncle muddy » Thu Dec 16, 2010 5:41 pm

They we go boys and girls all back :mrgreen:
UM

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