Sorry if this is rehashing old information. I poked around with the search function and found some stuff, but not everything I need.

I have a D60 at the axle shop now getting prepped and it's going to get disc brakes. The shop quoted a price of $475 for a kit; which doesn't seem bad at all, but I think I could get by significantly cheaper if I source the parts myself going with the Ford Explorer rear disc swap. There is a large self service junk yard near by, so getting the brackets should not be an issue. Rotors and calipers would be purchased brand new from a parts store.

Would there be much savings doing this myself, or should I just get the kit? If I do decide to source the parts myself, what year Explorers should I be looking at for caliper brackets?

I found this photo linked in another thread here:



These the brackets I should be looking for?

Thanks again.

Call your parts store and price it out... then call the salvage yard and price it out... then figure what your time is worth and ...you guessed it price it out. Let us know what you came up with.

Around here the backing plates are always damaged and usually rust out, from sitting with no wheels. I put an 8.8 in 2 of my vehicles, the one I had to replace everything on the brakes except backing plates, i want to say it cost like 300$ to replace everything.
I did see people selling complete used setups on eBay the other day.

Used to be a time FMS sold the Explorer rear disc kit all new for less than that quote. Doesn't seem to be so anymore, but that $475 quote is cheaper than any Explorer kit I can find these days.

Currie has new backing plates at a reasonable cost (Summit carries them) or you can buy the whole kit from Currie.

https://www.currieenterprises.com/CE-6012E1

I sell NEW Explorer rear disc brake kits for $395.

there you go, I knew I saw that kit somewhere

I thought you did but I couldn't find them on your website so figured they had gone away.

Not sure if this helps at all, but E350 vans came with Dana 60s and disc brakes from the factory.

I looked at your store before and didn't see the kit either. You also sell the Ford housing ends? Probably just make things a whole lot easier going through you and that is a good price. I'll call you Monday.

I don't stock the Explorer rear disc brake kit, but I can drop-ship it.

Billet steel "new style/Torino" housing ends run $80 pair.

I did the kit from Teraflex, uses explored rotors, calipers, etc.

i am assuming you are prepping this dana 60 for a car---using ford passenger axle ends----there is a disc brake set up on a lincoln mark 7 or a versaille that fits right on there...the caliper on it was re-used on the explorers---neat set up......

Got everything from Dr Diff to rebuild my 60 and also got the Explorer disc brake kit. The brake kit was only $390 and sure beats going junkyard shopping in the dead of winter. Honestly, even if this were summer I'd still go this route. The shop has everything now and I should pick the completed axle up a couple weeks after the new year. Thanks again Cass...

You need a big piston up front to work with the Explorer caliper out back. Are you using the factory calipers up front? If you have room for a 11.75 rotor (15 inch wheel) you might want to upgrade the front rotors. All you should need would be the bigger rotors and the taller caliper brackets. You shouldn't even need to bleed the brakes, just lift the calipers off and change the rotors and brackets and drop them back on.

I figured I would need to change the master and distribution block. The car has 18" wheels that I bought in that size specifically for upgrading the factory front disc to a 13" rotor. I do have the 11.75" brackets though. I may just do that and see how it works for now since the budget is shot already. Trouble is I don't want to change the master twice if I decide to go 13" brakes up front later. Eh, I'll figure it out in the Spring.

You wouldn't need to change the master twice. If you're going with 13 inch rotors up front then you can ditch the power booster and just run manual. You should be able to use a 15/16 inch master from Doctor Diff for 4 wheel disc brakes. You shouldn't need a prop valve with that setup so just a simple distribution block will work. If you want to keep the factory brake light then you'll need a distribution block with the switch in it. Which 13 inch setup are you going to use up front? I just got the 13 inch Viper setup installed on my Duster. That same kit should bolt on your car. I also have the Explorer setup in the rear.

Do you have a link to that rear brake kit, I couldnt find it.


Grr I read it through and found the answer.

Ive one S60 already with the explorer kit and its been flawless for almost 10 years now.

Like Andy wrote if you get the right master its very easy to run a manual system that works great, my fronts are a wilewood kit and ive also got the bigger master that came from Dr Diff and I might have a lil mos match as it takes more pedal effort then I thought it would but at the same time my front rotors are blue and my backs are a bit so maybe im working them hard.

I didn't realize going manual was an option. Would be nice being able to toss the booster. I was planning on Cass's 13" Cobra kit, but the Viper kit the two of you are putting together looks real nice too.

Do you think I would be able to run with the factory calipers up front for the season with a master cylinder that would be compatible with one of those two options?

Thanks again.

You could run a manual setup with the factory calipers and 11.75 rotors up front. It would stop but you might need to put more effort into it than you're used to. Once you changeover to the 13 inch rotors the effort would drop a bit.

I run manual brakes on my Coronet with 13 inch rotors up front. It stops really well and that car is 4000 lbs. So if you car is less than 4000 lbs you should be fine with manual brakes.