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Rear disc brake conversion

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Steve83

Re: Rear disc brake conversion

Banned User

85lebaront2 wrote

...coax the companion flange (Ford's term) off the pinion.

It has threaded holes that will work with a common bolt-grip (steering-wheel-style) puller.

ArdWrknTrk wrote

When I bought my Horrid Fate 'Pittsburg' puller...

I spent up for a used (ebay) SnapOn bar puller set, and a new OTC slide hammer set (which can also be used with its included standard-size pressure-screw; IOW same screw as the SnapOn).

On some older Honda front wheel hubs, I found it MUCH quicker to use the 4-slot frame on the lugs, but the slide hammer (hitting in BOTH directions) instead of the pressure screw. For whatever reason, that seemed to break them loose much faster than the pressure screw alone, or only hitting outward with the slide. That might be necessary for a stuck companion flange. The guy who regeared my disk swap axle said he & his son had a helluva time breaking mine loose from the pinion splines. Fortunately, I already had another flange cleaned & painted for him to use, so it didn't matter what he did to that one.

85lebaront2

Re: Rear disc brake conversion

Administrator

Steve, I actually used my Snap-On balancer puller with a pair of 5/16-24 X 1 1/2" Gr 8 bolts and some thick washers. I thought about the steering wheel puller, but didn't think it would be strong enough.

Here is the pinion being driven out using Ford tool T85T-4209-AH

Here is the 10 tooth pinion after removal, note the rusty area on the shaft, that is where the outer bearing was.

Bill AKA "LOBO" Profile

"Getting old is inevitable, growing up is optional" Darth Vader 1986 F350 460 converted to MAF/SEFI, E4OD 12X3 1/2 rear brakes, traction loc 3:55 gear, 160 amp 3G alternator Wife's 2011 Flex Limited Daily Driver 2009 Flex Limited with factory tow package Project car 1986 Chrysler LeBaron convertible 2.2L Turbo II, modified A413

Steve83

Re: Rear disc brake conversion

Banned User

85lebaront2 wrote

I actually used my Snap-On balancer puller...

That's what I was referring to as a "steering-wheel-style" or "4-slot" puller.

85lebaront2

Re: Rear disc brake conversion

Administrator

Ok, because I have a steering wheel puller, and no way would that have gotten it apart. Remember this is a 10.25" full floating from an F350 DRW pickup and everything is bigger and heavier.

Bill AKA "LOBO" Profile

Steve83

Re: Rear disc brake conversion

Banned User

I just realized that's a yoke - not a companion flange.

This shows those bolt-grip puller holes, closer to the center:

ArdWrknTrk

Re: Rear disc brake conversion

Administrator

In reply to this post by 85lebaront2

85lebaront2 wrote

Here is the pinion being driven out using Ford tool T85T-4209-AH

Ah Ha, Ford has a p/n for their hunk of bar stock!

Similarly, Smith & Wesson sell a cylinder timing tool.
It's a 1/2 lb chunk of lead and cost $40-50 back in the '80s.

Jim,
Lil'Red is a '87 F250 HD, 4.10's, 1356 4x4, Zf-5, 3G, PMGR, Saginaw PS, desmogged with a Holley 80508 and Performer intake.
Too much other stuff to mention.

85lebaront2

Re: Rear disc brake conversion

Administrator

In reply to this post by Steve83

Steve, I call it a yoke, but Ford's manuals for some reason known only to Henry I call it a companion flange. I was using their terminology.

Jim, it is internally threaded 1-18 so it screws over the end of the pinion and seats against the end of the splined area, there is also an installer that screws on the end, then has an outer section that presses the flange/yoke down against the bearing and slinger.

Bill AKA "LOBO" Profile

Bruno2

Re: Rear disc brake conversion

In reply to this post by Gary Lewis

All of the E series with the Sterling rear end use the 8 on 6.5 lug pattern. All the way to 2006 at least. They have been using discs on the rear since 99.

Whitey: 1996 F 250 XL CCLB 4X4 7.3 DI ZF5 (The Work Horse) Lots of power mods
Whitey Jr: AKA Jr 1982 F 150 CCLB 4X4 351W C6 (Jr Work Horse) respectable power, but not over the top
The Bronco: 1987 Bronco XLT 351W C6 (needs work) Lots of off road mods and plenty of power mods
The Dodge: 2006 Ram 2500 CCSB 4X4 5.9 HO Cummins (The reliable ride that cant keep an AC in itself) (5th AC go around almost complete)

Bruno2

Re: Rear disc brake conversion

Also, they have the internal cable operated parking brake. Not the type that bolt to the rear of the tranny.

Gary Lewis

Re: Rear disc brake conversion

Administrator

What's the distance between the spring perches as opposed to the F-Series? Do you have to relo them?

And is the track/overall width the same?

Gary, AKA "Gary fellow": Profile

Dad's: '81 F150 Ranger XLT 4x4: Down for restomod: Full-roller "stroked 351M" w/Trick Flow heads & intake, EEC-V SEFI/E4OD/3.50 gears w/Kevlar clutches
Blue: 2015 F150 Platinum 4x4 SuperCrew wearing Blue Jeans & sporting a 3.5L EB & Max Tow
Big Blue: 1985 F250HD 4x4: 460/ZF5/3.55's, D60 w/Ox locker & 10.25 Sterling/Trutrac, Blue Top & Borgeson, & EEC-V MAF/SEFI

85lebaront2

Re: Rear disc brake conversion

Administrator

E-series is narrower than an F-series. The later RV/box truck E350 rear disc setup could, in theory, be used on an F350 dually. Unfortunately my favorite junkyard doesn't have any yet.

Back to our regularly scheduled report. Wednesday I picked up a big bearing splitter at Harbor Freight in Salisbury. I found it wouldn't quite get the bearings completely off the differential. When I went to Virginia Beach Friday, I picked up a pair of 5/8-18 X 2" Gr 8 bolts to use to push the bearings off. Worked perfectly.

Next phase, pressed a new inner pinion bearing and a .015" shim (original had .025", new pinion has -10 on it). Assembled the pinion, less crush sleeve for a trial fit. Pressed new side bearings on the differential, and installed the new tone ring and 3.73 ring gear (same 41 tooth count as the 4.10, pinion is 11 vs 10 tooth). Put the differential in and with the starting shim size on the left, and all slack taken up on the right, I had 0 backlash. Removed .020 from the left side, added .020 to the right side, .009" backlash, tolerance is .008-.015, desired is .012-.015.

Time to roll a pattern and see where everything is.
Drive side:

Coast side:

Looks pretty good to me.

Bill AKA "LOBO" Profile

Gary Lewis

Re: Rear disc brake conversion

Administrator

Looking good, Bill! I've never done it, but I've read about it many times. And what I see in your pics look spot-on.

Gary, AKA "Gary fellow": Profile

85lebaront2

Re: Rear disc brake conversion

Administrator

You sure you didn't stay at a Holiday Inn Express?

Bill AKA "LOBO" Profile

Gary Lewis

Re: Rear disc brake conversion

Administrator

Several times, in fact.

Gary, AKA "Gary fellow": Profile

85lebaront2

Re: Rear disc brake conversion

Administrator

Ok, finally received the replacement yoke/companion flange yesterday afternoon via UPS, got the pinion preload set and intalled the differential and it's preload shim packs. I rechecked the gear pattern to make sure nothing had shifted and installed the rear cover, owner had sand blasted the outside and primed it (he's had it since labor day).

Then it was let's see if we can make the hydraulics fit. End result, shorten the two hard lines, mount the brackets for the hard line to hose connections to the rear of the spring pads so the U-bolts will clear.
Cover and center of brake lines:

Right end brake line:

Left end brake line:

Screws holding the brackets are old spare U-joint strap screws.

Bill AKA "LOBO" Profile

Gary Lewis

Re: Rear disc brake conversion

Administrator

Looking good, Bill! You'll have that thing back under the truck this week?

Gary, AKA "Gary fellow": Profile

85lebaront2

Re: Rear disc brake conversion

Administrator

Not my truck, John Gleason is so well organised if it gets under his truck by the end of the year I'll be amazed. He has a new bed to put on too. I recommended he remove the old bed first, then do the axle while it's easier.

Bill AKA "LOBO" Profile

grumpin