Dana 60 Brake Upgrades

[nonstop]

Hey guys, I have lurked here for some time, and finally joined. Figured I should introduce myself! This is a great wealth of knowledge on this board with a nice group of folks! My truck is an 85 K2500, which started out stock when I bought it 16 years ago. Since then, I lifted it, lifted it again, I think lifted it again, got older, and lowered it a little. As it sits, the truck is at 4 inches with 33's. During the time I owned it, I swapped axles to a full float 14 bolt rear with disc brakes and a Dana 60 front. I also converted to hydroboost and a C3500HD master cylinder.

So here goes the question. Has anyone found an easy and effective way to upgrade the front brakes? Don't get me wrong, the brakes work well, I just keep looking for even better! I have checked online and found people doing some crazy stuff adapting later brakes and making brackets. That sounds great, but I am missing two things to make that happen - money and great fabrication skills! I have a C3500HD dual piston caliper I am going to try. Has anyone tried this before and am I wasting my time, or are there any other suggestions that might be better?

Thanks,

Nick

[russgt]

Its a long read but interesting.

http://67-72chevytrucks.com/vboard/s...d.php?t=463042

I have a 76 K5 with a 60/14 combo, 4 inch and 33s as well. I am interested in what you come up with.

[86c20]

i got a k30 and would also like better.

[nonstop]

Thanks Russ, I read that thread, and that had gotten me fired up to check into various options. I was looking at the original calipers, and the piston is huge. But.....much of the piston is uncovered. This is only giving contact in certain areas of the pad. I was checking rockauto.com and found the C3500HD uses a Bendix caliper, but a twin piston 66mm caliper. The caliper is the same size as the original, but I am unsure if there will be piston clearance issues and how to over come them.

I was curious if this have ever been done.

[nonstop]

Okay, so for anyone thinking about upgrading their front brakes - here is what I was initially working with:

My brake system was factory front calipers (86mm) rear disc conversion with 3/4 ton (80 mm) front calipers, C3500HD master cylinder (40mm) with its spacers and hydroboost. The pedal was firm. There was not a lot of movement, and the brakes worked okay. I had tried a 1 5/16 master, but the brakes were too soft. It was also for a disc/drum set up.

I searched around and found the C3500HD offered a dual piston (66mm each) caliper on the wrecker package. It was also used on the P30 and Workhorse. They were Autozone P/N C595. I ordered up a set to put on. They fit in the stock space with some slight grinding to the caliper. The lower casting for the bore hit the knuckle slightly and I ground the casting and slightly on the knuckle. The other side needed slight grindng on the caliper only.

I ended up using all the parts that came along with the caliper, except the key. I used the old one, as it just seemed to fit better.

As for pads - I tried the C3500HD ones, but wayyyyy too big (would have been cool though). I used factory pads. I had to cut off the wear sensor and grind down the retaining nubs for it. I also ground flat any irregularities on the back of the pad. I only had to do this to the pad that fits against the piston.

As for braking - the pedal feels great! The truck seems to stop much better too. There is more contact on the brake pads, and they will wear more even. The old ones I took off had gouges in the backs of the pads from the piston and were worn unevenly.

[v30crewcab]

got any pics of yours installed? curious how well this works.

[nonstop]

I will try to get you some pics.

[Pico k30]

you said the pads are way too big what size are the rotors on the c3500hd

[andrewmp6]

Brakes off a ford dana 60 might be easier to swap on.Ford went dual piston sometime in the mid 90s but also went ball joint so swapping spindles might be out of the question.

[nonstop]

The rotors are 13.86 inches diameter and can't be retrofitted without a boat load of fab work. The calipers bolt right on and you can use the k30 pads.

[Pico k30]

gotta love autozone's measuring skills their site said the rotors were 12.5" like a k20