Autozone Expo Rear Disc Brake Swap - Ranger-Forums - The Ultimate Ford Ranger Resource


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Old 10-12-2010
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Autozone Expo Rear Disc Brake Swap

So I have a new-to-me 31-spline 8.8 that I got from a 03 Level II. It's awesome. Only problem is it doesn't have the disc brakes like the Explorer 31-spline 8.8s do. I read up on the how-tos on doing a disc brake swap but I am having problems justifying spending $300-$500 (more than what I paid for the axle itself) for the Ford swap kit, the Summit racing one is similarly priced. Not only that but it doesn't even come with everything!! So I've been looking around for a solution.

I could always go to pull-a-part and pull the axle shafts from an Expo and rape all the brake stuff. That would get me everything. But it will all be 10+ years old. Plus I would still need new hoses and I would want to replace the hardware.

So I am thinking I might just piece together a kit from Autozone parts. Here's what I got:

Brakes & Traction Control | 2000 Ford Explorer 4WD 6 Cylinders E 4.0L EFI SOHC | AutoZone.com

If you can't get it to show up set your vehicle on autozone.com to a 2000 Ford Explorer 4x4 with the 4.0 SOHC. That's what I used.

The list of brake parts on there has everything I need including hoses and bolts. The only thing they don't sell is the backing plates that you mount the calipers to. I found them at Currie Enterprises but they want $100 a side!! I will probably have to get those used. Unfortunately the ones at the pull-a-part are all bent to hell cause they rest the vehicles on them before that put them on on blocks.

Here's the list that I have in my cart right now.

Duralast/Brake Caliper Bolt/Pin (H5093) | Brake Caliper Bolt/Pin | 2000 Ford Explorer 4WD 6 Cylinders E 4.0L EFI SOHC | AutoZone.com
Morse/Brake Caliper Loaded Pair - Rear (P4604) | Brake Caliper Loaded Pair - Rear | 2000 Ford Explorer 4WD 6 Cylinders E 4.0L EFI SOHC | AutoZone.com
(Might get these used from pull-a-part as well since they are so expensive)
Duralast/Brake Drum All-In-One Kit - Rear (H7422) | Brake Drum All-In-One Kit - Rear | 2000 Ford Explorer 4WD 6 Cylinders E 4.0L EFI SOHC | AutoZone.com
Brakeware/Brake Hose - Rear (78738) | Brake Hose - Rear | 2000 Ford Explorer 4WD 6 Cylinders E 4.0L EFI SOHC | AutoZone.com
Brakeware/Brake Hose - Rear (78330) | Brake Hose - Rear | 2000 Ford Explorer 4WD 6 Cylinders E 4.0L EFI SOHC | AutoZone.com
(AZ says I need a brake hose lock for these. Not sure.)
(Brakeware/Brake Hose Lock (H1457A) | Brake Hose Locktrue | AutoZone.com)
Duralast/Brake Pads - Rear (D667) | Brake Pads - Rear | 2000 Ford Explorer 4WD 6 Cylinders E 4.0L EFI SOHC | AutoZone.com
Duralast/Brake Rotor - Rear (54032) | Brake Rotor - Rear | 2000 Ford Explorer 4WD 6 Cylinders E 4.0L EFI SOHC | AutoZone.com
(I might just get 2 of the best looking ones I can find off one a pull-a-part and have them resurfaced)
Duralast/Parking Brake Shoe (766) | Parking Brake Shoe | 2000 Ford Explorer 4WD 6 Cylinders E 4.0L EFI SOHC | AutoZone.com
Brakeware/Brake Cable (C9766) | Brake Cable | 2000 Ford Explorer 4WD 6 Cylinders E 4.0L EFI SOHC | AutoZone.com
Brakeware/Brake Cable (C9779) | Brake Cable | 2000 Ford Explorer 4WD 6 Cylinders E 4.0L EFI SOHC | AutoZone.com
(I heard that the driver side Ranger cable is compatible but I will need the passenger side. We will see)

Master Cylinder (Brake System) | 2000 Ford Explorer 4WD 6 Cylinders E 4.0L EFI SOHC | AutoZone.com
I'm not sure about the master cylinder since I guess every model had a different one. 2-door, 4-door, V8, V6 SOHC, V6 OHV, 4x4, 4x2. Not sure which one, or just run my stocker. I think I will play that one by ear.



So besides the backing plates does AZ have everything I need?

Last edited by Masteratarms93; 10-12-2010 at 10:49 AM.
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Old 10-12-2010
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Ok, so I added everything up. I left caliper, rotors, and parking brake cables off. My total is $150 plus tax from Autozone.

Pull-A-Part wants $7 per backing plate and $20 per rotor and caliper combo. So that would pull my Pull-A-Part total to $57 plus tax and fees.

Then NAPA charges like $12 to resurface drums so if rotors are the same it would be $22 plus tax from them.

So my grand total would be $229 plus tax and charges. I would need thread locker and brake cleaner. Plus new fluid if I do it after I put the axle in.

So a rear disc swap for $300 EVEN!!!
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Old 10-12-2010
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I love how everyone checks this thinking "Oh cool someone did a rear disc brake swap for cheap through Autozone." Then they saw I needed advice on it and they were like "Oh, newb, nevermind."

I love all the responses I get on here when I need help with stuff. Everybody and their brother gets in a thread when someone is mounting up a OHC but god forbid someone needs help with something that takes real mechanical skill.

Ok, I feel better. Taking out my tampon now.
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Old 10-12-2010
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lol pssh

So yeah your gonna wanna run something different for your proportioning valve. I think the only route to go is aftermarket unless the expo with discs have a different valve. Newer rangers have it built into the ABS system and it will regulate for disc automatically. Ours however do not. I still have yet to fully resolve that issue after I did my cobra disc swap.
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Old 10-12-2010
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Let me know how this works. I'd love to do the same thing on my level II axel.
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Old 10-12-2010
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Quote:
Originally Posted by StrangerRanger View Post
lol pssh

So yeah your gonna wanna run something different for your proportioning valve. I think the only route to go is aftermarket unless the expo with discs have a different valve. Newer rangers have it built into the ABS system and it will regulate for disc automatically. Ours however do not. I still have yet to fully resolve that issue after I did my cobra disc swap.
I thought all the rear ABS was inside the axle itself. So if I do a full rear axle swap and not just a rear disc swap with an 03 rear axle would it have the automatic regulation.
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Old 10-13-2010
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No. If your year truck is the one pictured then you probably have RWABS and its located under the hood next to the master cylinder. Changing the axle or the brakes will not change the breaking pressure and it will be VERY insufficient to stop your truck correctly. You can drive around just fine, but anything more then half pedal is all front brakes. You need to remove/change the proportioning valve that is located on the master cylinder. I have yet to do this to mine, so I have been just braking early. I plan on getting it done in the next week and I will post up here what I did and what it took
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Old 10-13-2010
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Quote:
Originally Posted by StrangerRanger View Post
lol pssh

So yeah your gonna wanna run something different for your proportioning valve. I think the only route to go is aftermarket unless the expo with discs have a different valve. Newer rangers have it built into the ABS system and it will regulate for disc automatically. Ours however do not. I still have yet to fully resolve that issue after I did my cobra disc swap.
i don't think too many put a proportioning valve in when doing the explorer swap. i have had my ex axle for about 5 years and didn't change the master, nor add a prop valve. i have 4wabs, but it's not worked for about 7 years as the wrong rotors were put on the front. i can stomp the brakes and the rears lock up just barely before the fronts.
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Old 10-14-2010
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I'll give some info to clear up any confusion.

2000 Ford Ranger XLT RABS 2WD
2003 Ford Ranger FX4 Level II Rear Axle with 10 inch drums and ABS
2000 Ford Explorer Rear Disc Brakes with ABS

I know for a face that the ABS for the rear brakes is set by the ABS ring in the differential.

With my truck there is an ABS pump thing next to my battery.

I can replace that valve I need to know which model to get it from. Especially since I only have RABS. I don't believe there was an Expo with only RABS.
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Old 10-28-2010
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Any updates on this? I've been thinking about doing the swap myself..

I just like to follow along on others progress.. PICS MAN PICS!!!


GB :)
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Old 10-28-2010
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No progress. Don't have the money to do it. I'm just glad I got the axle on before the winter.

I did go a Akron Pull-A-Part to do some investigation. I looked around and picked the expo with the best looking rear brakes and started to pull them. I got the axle shafts out (glad that I tried this on a beater before I do it on my Ranger) and got all the driver side off. Got stuck on the p-brake cable though. Didn't bring a hack saw with me so I had to leave everything. Never got a chance to go back.

All I know about this swap is you can get ALL the parts at auto part places EXCEPT the backing plates. These are ONLY obtainable through Ford or at a JY. I was personally also going to use JY rotors and calipers as they were the other 2 most pricey parts of the swap.

Everything else was going to be though AZ.
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