My DIY Rear disc brake conversion

[Peanut74]

Since this board has helped me so much I thought I would share this information. Since I wanted to convert to 5 lug I thought I might as well convert to disc brakes. Didn't like the cost of the conversion so I came up with this.
1) Converted to 5 lug using Yukon kit 21835, but it had drums with the kit
2) Used the rear rotors from a 2005 Chrysler Pacifica (Had to drill and put roll pins in to take up the extra space between the axle and rotor.)
3) Used grade 8, 3/8" x 1-1/2" bolts to attach the spacer and bracket to the axle. Cut 3/8" off the caliper bracket bolts as they hit the rotor.
4) Bolts installed in axle housing
5) Spacer installed on axle
6) Caliper bracket plate installed and torqued down
7) Caliper bracket installed and torqued down
8) Installed the 2005 Pacifica caliper and new pads
9) Axle installed on chassis
10) The spacer and bracket I made out of 3/16" material. (Son in-law drew them up and cut them out on a laser table) I had to drill one hole in the spacer and bracket slightly as one hole was off by 1/16". For the caliper bracket one hole was off by about 1/32" just enough so I couldn't bolt it up.

In hindsight I would have preferred to use a 2012 Jeep Wrangler rotor and have the axle hub machined down to match the rotor. For the Pacifica rotors the hub opening is larger than the axle hub. So I used roll pins to take up the slack space.

I went with the e-brake delete option to ease the design of everything. As I refined the bracket I made test bracket out of plywood to work out the bolt pattern and caliper bracket hole placement.