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Years ago I was super keen on switching to rear disc brakes, but now I wonder if there is really any point. After owning many cars with front drums, I can certainly see the advantage of front disc brakes.
But for the rears, drums seem to be able to lock up any time needed, even after a few hard stops.

Also I find front discs / rear drums the easiest setup to work on.
 

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1998 ZX2
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Well, I pulled the trigger on the brackets. I don't know when I'll do the conversion but the page says they are discontinued and that once stock gone there won't be anymore. Even if I don't use them I'm sure I could sell them for what I paid. The link for the page changed, this is the current link if anybody else in intrested. https://kainjection.com/products/rear-disc-conversion-bracket
 

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I'll be doing this conversion (hopefully) this weekend. I also opted to get some rear proportioning valves in addition to everything else. The one thing I believe I may end up needing is the rear disc brake master cylinder as the threads for the prop valves on the master cylinder itself MIGHT be different, however I read that hyundai prop valves are identical to rear disc prop valves and will be testing that theory.

I have:
Rear Discs/Pads
EBC-GD639
PWR-Z23-636
Rear Calipers
Motorcraft 45553 / 45554 Reman (found out the hard way these were so cheap because they don't come with the mounting brackets)
Rear Caliper Mounting Brackets
Cardone 14-1087 Reman
Rear Caliper mounting bolts (May not need these? I need to look at the KAI bracket hardware)
Raybestos H17008
KAInjection disc conversion bracket
Rear Disc Parking Brake lines

AGB-BC95726
AGB-BC95730
Stainless Braided Lines w/ Rear Discs
Techna-Fit FOR-1910
Hyundai Sonata Rear Disc Proportioning Valves
58775-36900
 

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Hit a snag tonight, left wheel hub/bearing doesn't want to come off easily. My 3 jaw puller is broken and I never replaced it, go figure. This will probably get pushed to next weekend instead.

Also, I looked in my parts of stuff to install in the future and found I ordered
Wearever Disc Brake Caliper Guide Pin Kit Part # 14100

Not sure where this will actually go (maybe these are the slide pins? edit: this does seem to be the case, but not 100% sure), but I did order it for the swap.

Also I discovered at least one of my rear struts was loose, so that should make the ride a bit better. Was wondering what that clunking was when I hit bumps on the highway.
 

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Successfully completed one side, save for the parking brake cable and the prop valve. So far everything works well. When I pulled the wheel hub off, the bearing actually left the inner race behind, I wiped it down and inspected it, no pitting or excessive wear as far as I can tell. I ended up just pressing the hub back on and saving that problem for the future.

If anyone else is tackling this, the hubs must come off to remove the drum brakes and install the KAI bracket and is a good time to replace those. I assume there is a difference between the drum hubs and the disc brake hubs as they are different part numbers, does anyone know what the actual difference is? This would be pertinent information if anyone is planning to get new disc brake knuckles from Mazda. I am also very curious what if any difference there is with Miata rear brake calipers/mounting bracket if any.

As for answering my earlier question, the "guide pins" are indeed the slide pins that mount the caliper to the caliper bracket.

Also, the KAInjection bracket DID come with mounting hardware for the caliper bracket, so the Raybestos H17008 was completely unnecessary in my case. However, the Raybestos hardware did come with thread locker where the KAI hardware did not. My calipers did come with the small rubber boots for the slide pins, so I ended up with a bunch extra (I ordered brake hardware with the pads). They also came with the copper crush washers for the banjo bolt.

One thing I am missing, but isn't strictly necessary is the dust shield that covers the back half of the rotor.

I should probably document all this in its own thread...


 

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Went to hook up the parking brake cables today, unlike the drum brakes the bracket to mount the cable to the caliper is a separate piece. Looks like I need to order:

Mazda 323 cable brackets:
BW0H26861
BW0H26851
2 of these bolts from Mazda:
BW0H26680

I thought maybe the old mounting bolts for the drum parking brake cable bracket would work, however it did seem like they were a different thread pitch (could have picked up the wrong bolt though).
 

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Good that you noticed the different thread pitch before installing those bolts. Lots of guys would get it started one turn or maybe a little more, then screw them in and screw them up.
 

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Thanks for posting all the part #s. I bought one of KA's brake adapters, they also list some chamber plates as dsc.

I won't worry too much about the proportioning valve, stock cars usually have way more front bias. Try it out first , the real test would be a wet parking lot turning hard trail braking.

Remember, if the rears lock first, round you go, fronts lock- no steering.
 

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Thanks for posting all the part #s. I bought one of KA's brake adapters, they also list some chamber plates as dsc.

I won't worry too much about the proportioning valve, stock cars usually have way more front bias. Try it out first , the real test would be a wet parking lot turning hard trail braking.

Remember, if the rears lock first, round you go, fronts lock- no steering.
I should have some snow heading my way this week, if it gets significantly slick enough I might try it without the prop valves. The logic in my head could be wrong, but I think this would be best case scenario as this would have the least amount of weight transfer to the front meaning that the rears should lock up closer to when the fronts lock up compared to better traction scenarios where you are lifting weight off of the rear meaning theoretically the rears should lock up before the fronts comparatively.

This is based on what I have read that adding stickier/wider tires may require adjusting brake bias towards the front as to not lock up rears.

If I get sufficiently motivated enough I may do some 60-0mph (or whatever makes the most sense) brake testing with and without the hyundai prop valves (would be nice to get my hands on some proper OEM rear disc brake prop valves for such a test). Maybe for fun I'll modify a set of prop valves with no proportioning for the test as well.

I requested pricing for the brackets from my local Mazda dealer today.
 

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Discussion Starter · #30 ·
I'm honsetly happy to see someone picking up the torch and finishing what I started. Life is kinda crazy for me right now and to put it blunty. My little escort is about 800miles away from me now waiting for my return. Good job and good luck Apex.
 

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Currently troubleshooting the parking brake system, not sure if the Mazda bracket is not compatible, the parking brake cables are bad quality, or if I'm doing something wrong. However, I did go ahead and break in the brakes, pretty happy with the braking performance after the swap. So far no rear lockup even without swapping the prop valve. We've still had really nice weather here so not sure when I'll get some rain or snow to try and lock up the brakes.
 

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I'm still collecting parts for the brake swap,
Is this the bracket in question?
I found this on rock auto - Escort 93 gt

NUGEON 9901130A


Motor vehicle Auto part Nut Nickel Metal
 

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Looks like that's the caliper including the mounting brackets AND the parking brake cable brackets! Good find. That whole caliper assembly is the same price for what I paid for the motorcraft calipers alone (no mounting brackets or parking cable brackets). I know there were some differences with the EGT rear brakes, but I think that was mostly with the suspension/spindles. Maybe someone else can comment?

Just so you know the parking brake cable brackets are side specific (including each parking brake cable bracket).

I just noticed the picture you included looks like it has some clips presumably for the cables, I bet you that's exactly what I'm missing, just need to track those down. Then again, maybe that's just the normal brake hardware.

Edit: here's the part numbers according to Rock Auto for the 3rd gen NUGEON 9907866A NUGEON 9907866B

They're a bit more expensive than the EGT calipers.
 

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I order the Nugeon calipers for my year chassis, 92.

One came with the E brake bracket and one didn't, go figure.

Joystick Game controller Input device Gadget Gas




Looks like the Mazda part # Apex provided will work up to 07. Thanks, that's less research.

Apex, How does your brake set up work in the snow and ice? Do you have any pics of the install?

Seems like this brake theme has been started many times and never finished.

JC
 

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Yes I'll upload a few pictures here in a bit, mine are completed less the rear dust shields and parking brake cable clips on the caliper brackets.

I'm not sure the Mazda brackets are an exact match to the originals, I was unable to get my parking brake cables to sit in them firmly, but I also have not found a source for the clips that are supposed to go on the parking brake cables. That being said, I have not had any issues with the parking brake with them "loosely" sitting in the brackets. I wasn't confident in it at first and I was always parking in gear, however I have never had the car roll when testing it on an incline and I've had it installed since the end of November.

I did practice locking up the brakes, the car never oversteered from braking with the pedal like the rear brakes were locking up, but I wasn't being dumb with the car either. I have not had a second person with me to see which tires lock up first though. I did frequently use the hand brake to induce oversteer when the car would understeer when going around a corner and that worked great. Very happy with the braking performance, though I honestly couldn't tell you with 100% certainty if it stops faster than before, but it certainly FEELS like it does.
 

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You got me thinking about this clip so I went out and looked the best I could ( unheated garage and front is jacked up doing bushings ) it looked like a brake hose clip.

Went to the Mazda parts site and started looking this is what I found.

Mazda wants $3 something a clip - Rockauto - 25 for $7 bucks . This is for a '92 Protege

Circuit component Gesture Font Parallel Auto part
Handwriting Gesture Rectangle Font Slope
 

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Does anybody know if the dust/splash shields actually fit with the conversion brackets? They are shown as still available from Mazda. I still need to get the front dust shields for my ZX2 since they are missing.
 

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Best I could tell the clips for the parking brake cables where they sit in the bracket are different than the normal brake hose/parking brake near the equalizer bar clips. My plan if I was having issues was to find a snap ring that would hold the cable in the bracket nicely, at least that's my theory, no idea if that will actually work. If anyone could post a clear picture of the OEM clip that would be amazing.

Oh, and make sure to paint your calipers, I assumed incorrectly that the calipers had a coat of paint on them when they were remanned, but they are already developing surface rust.

Here is the drum fully removed, note that my wheel bearing came apart leaving the inner bearing race stuck on the spindle, the original drum parking brake cable can also be seen tucked behind.


KAInjection adapter mounted, note that I believe the splash guard would fit behind the adapter with no issue as it is very thin metal, but I didn't think about even ordering one until after I fully assembled everything.


Caliper bracket, caliper, stainless brake line installed. The parking brake adjustment was a little tight so the pads were dragging ever so slightly on the rotor. Note that the adjustment is a security-type screw head (I honestly don't remember if it was security hex or security torx).


I don't have any photos of the parking brake cables unfortunately as I had to order the brackets afterwards and didn't take pictures when I did install them.
 
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