Dana 30 brake issues

[EnlistedManche]

So i recently swapped my dana 30 low pinnon disconect axle, with a trussed dana 30 high pinnon axle and new my brake pads on the new dana 30 are constantly rubbing against the rotors. For the life of me i can't figure out why my only guess is the the calipers are different in years. if anyone has any insight i would really appreciate it!

 

[HOrnbrod]

What did your new Dana 30 high pinon axle come from?

[Rockfrog]

There were only two types of caliper used, AMC and Chrysler, neither is compatible with the other.

There were 3 types of rotor used though.

 

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[EnlistedManche]

it came from a 96 plus cherokee at the junkyard i pulled, but for the life of me i can't recall the year i want to say it was a 97 or 98 and my comanche is a 91

[Eagle]

I've posted this before. It's from the unfinished manuscript of a book I started to write several years ago:

 

 

All Cherokees and Comanches used front disc bakes with ventilated rotors. However, not all years are the same. The original AMC design called for all cast rotors. Beginning in model year 1990, Chrysler used a two-piece composite rotor. This composite rotor was prone to two problems. The composite design consists of a cast outer rotor for the actual braking surface portion of the assembly, with a thin, stamped metal “hat” section where the assembly fits over the hub. The composite rotors warp very easily if worked too hard, or if the lug nuts for the front wheels are not carefully tightened to a uniform torque setting. Secondly, in northern states where salt is used on the highways during winter conditions, the thin metal “hat” section often rusted severely enough that the rotor itself detached from the “hat,” resulting in a complete loss of front brakes. There is a factory recall covering the front rotors on certain years in those states comprising the so-called “rust belt.” If you own a Cherokee or Comanche built in model years 1990 through1999, it is strongly recommended that you call a dealer or directly to DaimlerChrysler’s customer service number to inquire if your vehicle is covered by this recall. Have the VIN (Vehicle Identification Number) available when making the call.

 

In mid-1999 the front brakes were changed again, reverting to all cast rotors. However, the new cast rotors are not the same as the original AMC cast rotors. The various rotors and hubs have slightly different offsets, which means that in swapping axles or upgrading brake components to those from a different year vehicle, it is critical to keep the parts from one group together. Failure to observe this precaution will result in brakes that hang up or calipers that interfere with the rotors.

 

In general, the parts to be concerned with in keeping the front brakes compatible are the steering knuckles, the hub/bearing assemblies, the rotors, and the calipers. (There is a more complete enumeration of the interrelationship of these parts in Chapter 6, Axles.)

• Only two steering knuckle designs were used: 1984 through 1989, and 1990 through 2001. Left and right side knuckles are different part numbers within each group.

• Three different hub/bearing units were used. The hub/bearing units are the same for both sides of the vehicle. The different years for hub/bearing assemblies were: 1984 through 1989; 1990 through mid-1999 (composite rotors); and late-1999 through 2001 (cast rotors).

• Three rotor types were used: 1984 through 1989; 1990 through mid-1999 (composite); and late-1999 through 2001 (cast).

• Only two caliper types were used: 1984 through 1989, and 1990 through 2001. Left and right side calipers are different part numbers within each group.

 

As when I have posted this before, the above is copyrighted and I am NOT granting permission to copy it or to reproduce it and distribute it. Feel free to use the information for yourself, but please respect my copyright.

[HOrnbrod]

it came from a 96 plus cherokee at the junkyard i pulled, but for the life of me i can't recall the year i want to say it was a 97 or 98 and my comanche is a 91

 

Okay. Did you then purchase and replace new calipers, rotors, and/or pads on the new HP axle? Or just bolt it in reusing the existing, hook up the brake lines, then bleed? Just trying to determine if you might have installed the wrong brake parts for your axle.

[Rockfrog]

Yeah, answer the above and we'll have a better idea of where to go. If they are used calipers, they may simply need to be replaced. The stock Chrysler calipers had a habit of seizing when left to sit for long periods of time (well, and whenever they felt like it as well it seems). As further many caliper designs have a tendency to seize when left to sit as well. If they sat for a long time (in caliper speak anything over about 5 months) that may be the issue.

 

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[Eagle]

So i recently swapped my dana 30 low pinnon disconect axle, with a trussed dana 30 high pinnon axle and new my brake pads on the new dana 30 are constantly rubbing against the rotors.

 

Out of curiosity -- you mentioned in a follow-up post that your truck is a '91. But you say it had a low-pinion front axle. What did the front axle come out of? ALL MJs had high-pinion front axles -- Jeep didn't switch to a low pinion D30 in the Cherokee until model year 2000.

[EnlistedManche]

yes thats correct it was a HP dana 30 disconnect (my bad), that i swapped for a HP dana 30 Non Disco. I did the whole swap in the morning so i unbolted the calipers from my HP 30 DISCO and used a bungee cord to hold them up until the new axles was ready to go in. I used the same calipers and rotors. with out disconnecting any brake lines

[HOrnbrod]

Here's the parts manual data:

 

CALIPERS (Same)
91 Caliper 4WD:  5252984-5
97 Caliper 4WD: 5252984-5
 
ROTORS (Different p/n's)
52008440, 1990-91
52007710, 1992 (Up To 2-10-92)
52008264 superceded to 5016434AA, 1992 (After 2-10-92) and up to 2001

 

So it looks like the calipers are the same, but the rotors carry a different part number after 1992. What the difference is I don't know. Maybe the offset of the old rotors on your newer axle is different causing it to not be centered between the pads.  :dunno: You would have to compare the rotors side-by-side. From the p/n data it looks like it should all play together fine with the newer rotors. 

[EnlistedManche]

Thanks! i'll have to look into that. I just realized it might be the splash guard that are touching the back side of the rotor as the had gotten a little bent up from moving the axle around. i did my best to bend them back but ill have to check for sure hopefully later today

[64 Cheyenne]

My suggestion is to leave the dust shield off when you get it apart next time. Rocks and other debris has a way of finding its way between the rotor and dust shield causing odd squeal scraping noises. I always leave mine off, and on the 8.8 it's cut above the step off line so it can still hold e brake components. (the dust shield)

[EnlistedManche]

yup it was the dust shield. I took an angle grinder to it instead of trying to fight and get the hub off! it was also rubbing just slightly on the knuckle which is weird so i'm assuming there is a slight difference in the rotors. i plan to go get new ones for a 2000 model next week sometime. thanks for all who replied and the information you guys rock.