Rear Drum Brake Conversion to Discs

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Rear Drum Brake Conversion to Discs

Postby astromo on Mon, 18 Apr 2022 1:08 +0000

Hi all

First time post. Haven't needed to seek advice before.

I've got a 6th Gen 4x4 1999 Hilux, LN167 and have had idle thoughts for some time about the value of disc brakes on the rear end.

I'm in the process of upgrading the headlights to LEDs and in the process of researching kit to source for that job, I stumbled across a relevant youtube post by the bloke from Boosted Built Garage (BBG).

He's put together, tested and sells a 6th Gen Hilux conversion bracket system to permit installation of Nissan GQ Patrol discs in place of the rear drums. To go this path, the hand brake needs to be replaced, so he's also put together a transfer case hand brake kit.

I'd be interested to know whether anyone out there has had experience with the BBG or any other kit that's on offer.

I'm a punter who doesn't have access to a full blow workshop like old mate from BBG, so what he offers appeals because it appears to offer a numpty friendly solution for the likes of myself.

To go down this path, I really need a Lego-style option where ideally the relevant bits are:
  1. Readily available;
  2. Don't require crazy automotive surgery to put together;
  3. Involve a relatively painless process to gain modification plate approval (I'm in Qld FWIW); and,
  4. Preferably do not cost stupid money to make it all happen.

Constructive input welcome. I'd be happy to gain from the experience of those who've "been there and done that" and would value the prospect of avoiding traps, pitfalls and general aggravation. Thanks.
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Re: Rear Drum Brake Conversion to Discs

Postby dave g on Mon, 18 Apr 2022 8:29 +0000

how much do you spend on a 23 year old truck ??
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Re: Rear Drum Brake Conversion to Discs

Postby Richard on Thu, 21 Apr 2022 9:26 +0000

Does BBG offer blue plate?

Pedders offer a certified rear brake upgrade to disc but you're looking at over 4 grand unfortunately.
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Re: Rear Drum Brake Conversion to Discs

Postby astromo on Thu, 21 Apr 2022 11:32 +0000

Richard wrote:Does BBG offer blue plate?

Pedders offer a certified rear brake upgrade to disc but you're looking at over 4 grand unfortunately.


Thanks for the interest.

Regarding approval, no. BBG leave that to the individual. For Qld, the mod plate assessment would be against category LG2 from the research that I've done to date.

The Pedders kit suits Gen 7 Hiluxes to the best of my knowledge. Also, given they've done the design leg work, I'd expect it would pass in at LG1. Don't know for sure.

If I did, I wouldn't need to ask.

The journey has just started for me on this one.
Last edited by astromo on Fri, 22 Apr 2022 6:35 +0000, edited 1 time in total.
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Re: Rear Drum Brake Conversion to Discs

Postby 241steve on Fri, 22 Apr 2022 4:08 +0000

When I drove a 90 series, I drove a hilux with the pedders rear disk conversion on it, at the time I remember commenting the 90 series braked better than the lux that was when the owner told me it had a disk brake upgrade. Like everything else about gen 7 that upgrade is nothing to write home about.
I'm not a great fan of my lux if it wasn't a ute Id piss it off tomorrow and buy another Prado.
Too much outlay for too little gain. It is what it is.
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Re: Rear Drum Brake Conversion to Discs

Postby astromo on Fri, 22 Apr 2022 6:58 +0000

Just spoke with the guy that runs the workshop that I've been using since I got my clutch done (about 7 years and 60,000 km ago).

They're a performance shop that specialise in remapping engine management units and chucking the vehicle on a dyno as part of the exercise.

Turns out they've done more than one BBG unit in the past. In summary the advice I got was that the basic concept (including transfer case park brake) is fine. I was given a "you must" when it came to upgrading the brake master to a 1" bore unit from the standard 13/16" gear. Personally, I'd throw a double diaphragm booster in the mix with that for good measure. The last key piece of advice was to source used original components for the major hardware (rear callipers, brake master, brake booster) and then get them reco'd. Probably a more expensive way to go but I don't see the sense in applying half measures when it comes to a safety system.

Regarding getting the BBG kit passed through the mod plate process (subject to the good sense noted above) apparently from my source of intel, it's no biggy.

I'll be waiting a little while for this one. I've got sensible 15" wheels and the advice from BBG is that standard 15s will clash with the rear callipers. So, I'll get some 16s at the next tyre change.
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Re: Rear Drum Brake Conversion to Discs

Postby astromo on Fri, 22 Apr 2022 8:56 +0000

241steve wrote:When I drove a 90 series, I drove a hilux with the pedders rear disk conversion on it, at the time I remember commenting the 90 series braked better than the lux that was when the owner told me it had a disk brake upgrade. Like everything else about gen 7 that upgrade is nothing to write home about.
I'm not a great fan of my lux if it wasn't a ute Id piss it off tomorrow and buy another Prado.
Too much outlay for too little gain. It is what it is.


If that's the way you roll, maybe head here:
Converting the Prado to a Dual Cab Ute

Pedders doesn't offer a Gen 5/6 relevant kit, so I'm not seeing how your observation relates. Have fun with the Prado.. ;)
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Re: Rear Drum Brake Conversion to Discs

Postby ptrl1600 on Wed, 27 Apr 2022 7:30 +0000

astromo wrote:
I'd be interested to know whether anyone out there has had experience with the BBG or any other kit that's on offer.

Constructive input welcome. I'd be happy to gain from the experience of those who've "been there and done that" and would value the prospect of avoiding traps, pitfalls and general aggravation. Thanks.


Hi astromo, I have done the BBG conversion to my Series7 Hilux and it's probably the best mod that I've done for the money spent. Coming from a GU Patrol to a Hilux was a big disapointment in the braking department, particularly with the handbrake. (And I still can't believe they produce cars today with drum brakes)

The conversion was really easy to do - probably the most dificult part was bleeding the brakes with ABS. And the parts were all really cheap with the handbrake assembly being the most expensive. This conversion has many positive aspects but I can't think of any negative ones. Over the years I've had to replace rear wheel bearing seals and the drums make it very difficult and complicated to do - no longer the case. Also the constant adjusting of the drums and hand brake was a pain - no longer necessary to do. But the best thing is that the hand brake now actually works!

Image

I bought all new components on eBay - I don't see the sense in reconditioning old components when they are so cheap to buy new. I also replaced all the flexible lines with steel braided lines to improve pedal feel. The only thing that I didn't replace was the master cylinder thinking that I would see how the original one went and it works just fine, so it's still there. The pedal feel is softer, but the car pulls up much quicker without anywhere near the effort than with the drums. In fact I can now lock up all the wheels, which is something that the car would never have done previously.

Image

I have 16" wheels, so didn't want to go to Prado front brakes and have to change to 17" rims, so upgrading the rears seemed like a viable option and personally I'm very happy with the braking improvement.
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Re: Rear Drum Brake Conversion to Discs

Postby astromo on Thu, 28 Apr 2022 9:54 +0000

ptrl1600, thank you for the excellent feedback. It's gratifying to read a user opinion that confirms that the modification is worth doing.

[EDIT: any comments / feedback on the process to get the modification signed off?]

My brother in law had a Gen 7 Hilux and was very disparaging of its handbrake. Having driven it a couple of times, I couldn't argue with the scorn he laid down on it. The drum handbrake on my Gen 6 works fine when adjusted. I won't miss the labour charge from the workshop though to keep it functioning to a workable standard.

I get your point about opting for new after market kit. The shop I go to is old school and their priority is to be able to sign off on a functioning brake system when it leaves their hands. That's why they impressed upon me the importance of upgrading to a 1" bore master from stock. I was going to anyway but their experience with customers going the minimalist path was such that they've formed some strong views about the sense of that.

I also gather they don't want any boomerangs. If they do a reco themselves then there's no finger pointing anywhere else. They've taken the rap over some parts they fitted that didn't go the distance, so I know they deliver on that point. Each to their own on how they want to travel.

It's good for all of us to share this sort of experience. Thanks for sharing yours. Hopefully, I'm not the only one who will benefit.. ;)
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