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Gen1 Montero SWB 4-cylinder front brake upgrade

Posted By: Struc

Gen1 Montero SWB 4-cylinder front brake upgrade - 10/23/14 02:24 AM

I've seen some threads on the swap, but nothing from the small 4-cylinder brakes to Gen2 brakes, and nothing that I would consider a "how to", so here it is.

I had my front right caliper seize up on me, so rather than replace it with another anemic caliper, I decided to swap in the Gen 2 brakes.

I used rotors, pads, and calipers from a 1998 Montero Sport.
Master Cylinder from a 1998 Montero Sport as well.
You will also need to replace the bolts that join the hub and brake rotor, as you will see.
New brake lines (I bought -3an stainless lines & M10 to -3an adaptors on each end)

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Look at how pathetic those brakes look compared to the tires! <img src="/forums/images/graemlins/lol.gif" alt="" />

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Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 02:37 AM

First step is to remove the brake caliper & bracket, then start taking apart the locking hubs.

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Unbolt and remove the locking mechanism.

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Remove the circlip from the end of the axle shaft.

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Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 02:45 AM

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Remove all the bolts

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And remove the body of the locking hubs.

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Remove the 2 screws on the nut retainer

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They may be pretty tight, so a proper impact screwdriver is a huge help

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And then remove the nut retainer.

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The nut *should* be fairly loose, so you should be able to spin it off with a small screwdriver in one of the holes.

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Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 02:52 AM

At this point, you should be able to pull off the hub & rotor assembly.

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Clean off all the old grease

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Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 02:57 AM

If you are not replacing the shield, it needs to be trimmed back to fit the new calipers.

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I used my air cut off tool, but tin snips should work as well.

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Finished Product:

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Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 03:04 AM

Time to clean up and inspect the bearings

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And pull and replace the rear grease seal

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Dig out all the old grease

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Cut apart plastic container (in this case, laundry detergent) for a parts cleaning bucket and a can of brake cleaner, and CLEAN!

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Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 03:17 AM

Time to pull the hub apart from the brake rotor

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Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 03:35 AM

Some pictures comparing the old small rotors to the new larger ones.

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As you can see, the old bolts that hold the rotor to the hub have a unthreaded shank that is too long, and they cannot be used.

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Replace with new shorter HARDENED bolts, and new washers and nuts.

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Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 03:49 AM

Now... it's time to get dirty! - well, full of grease anyway. My grease of choice for this job...

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Pack the center of the hub, between where the 2 bearings sit with grease

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I won't go into how to pack bearings with grease... There are plenty of tools, or YouTube videos on how to do that. Install the rear packed bearing, and install the new rear grease seal.

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Once you have that done, reinstall the rotor/hub assembly on the vehicle. Make sure you smear a little grease on the lip of the rear seal before installing

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Then install the outer bearing

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And then the ring nut

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Hand tighten the nut while turning the rotor

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Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 04:11 AM

You need a special tool to tighten the nut to spec. I opted to buy this one (which came with 4 prongs instead of 2), and to take my cut off tool to 2 of the prongs.

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Use the tool to tighten the hub nut to 94-145 ft lbs per the manual. I like to do this in steps while turning the rotor in the early part to make sure the bearings seat properly.

Once torqued down, loosen the nut completely, and then re-torque to 18 ft lbs. Then, loosen 30 to 40 degrees (less than 1/8th turn).

According to the manual, you are then supposed to measure the amount of force it takes to turn the hub assy. I didn't personally bother, but if you have the tool, by all means go ahead. Spring scale reading should be 1.1 to 4 lbs.

Once all that is done, install the lock washer and install the 2 screws.

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Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 04:20 AM

Time to clean up the locking hubs.

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Remove the snap ring holding everything together

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Once apart, clean all the parts. There is another snap ring holding the remaining parts together.

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Reassemble the reverse way, and apply a thin layer of grease to all the parts.
Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 04:26 AM

If you keep the dust shield like I did, you'll probably need to bend up the lip for clearance a little.

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Install the Caliper bracket, caliper, and pads. Be sure to put a thin layer of grease on the pad hardware.

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I also use grease on the back of the pads to help eliminate any brake squeal.

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And... Installed!

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Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 04:36 AM

Install the locking hub body.

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Install the circlip to the end of the axle. PLEASE NOTE that it only goes on one way. There is a flat and rounded side to the circlip. It's been a while since I did this, but if I remember correctly, the flat side faces out toward you.

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If you take apart the locking mechanism, PLEASE note that there is a little detent ball and spring. DON'T lose them!

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Reinstall the locking hub mechanism, and you're nearly done.
Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 04:53 AM

I neglected to take many pictures of my brake line setup, but here are some stock pictures, and a couple of actual pictures of what I used, and where.

For the caliper, Earl's Performance 592032ERL Fittings:

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For where the hard line comes down into the wheel well area, Earl's 989538ERL or 989545ERL fitting:

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Used here:

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and then used a -3an stainless line with a 90 degree bend on one end (caliper end). The ones I got were 21" long. You could probably get away with 18", as long as one end has the 90 degree bend.

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This all eliminates the 3 piece brake line setup that is stock. I ran the stainless line through the bracket, wrapped some electrical tape on it to prevent vibration from wearing through it, and zip tied it tight.
Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 05:13 AM

Now, because the volume of the 2-piston calipers is so much greater, you really need to replace the master cylinder with the upgraded one as well. Because the stock master cylinder has a brake tee built into it, and the new one doesn't, you'll have to adapt. I got one of these:

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It's advertised on Ebay and Amazon as a VW Dune Buggy part, but it's just a metric (10mm x 1mm) brake line tee.

Then, with another pair of the Earl's Performance 592032ERL Fittings and a 9" -3an Stainless Line, here is the finished install:

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Properly bleed the brakes (have a VERY large container of brake fluid on hand). Start with the rear, and then the passenger front, then driver's front.

Done!! Enjoy your new braking power!
Posted By: rxinhed

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/23/14 10:13 PM

Awesome write-up. The MS backing plates wouldn't work for the Gen I hub? Curious about that. <img src="/forums/images/graemlins/kewl.gif" alt="" />
Posted By: Struc

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/24/14 03:52 AM

I believe they do, from other things I have seen on the forums, but I just didn't bother.
Posted By: JARED

Re: Gen1 Montero SWB 4-cylinder front brake swap - 10/27/14 11:44 AM

Great write up - this should be a sticky; looking forward to getting this done myself shortly
Posted By: OConnor

Re: Gen1 Montero SWB 4-cylinder front brake swap - 04/10/19 09:46 AM

Great write up, used your directions for my 91 LWB brake conversion.
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