Jeep TJ and YJ Wranglers are currently two of the hottest rigs for modification. They are cheaper than JK Wranglers, more common than CJs, and can be outfitted with tons of accessories. However when you add the weight of bigger off-road tires, beadlock wheels, and winch bumpers, they certainly don't stop that well. And then when you hot-rod them up with a V-8 you're just looking at a fender-bender waiting to happen.
Luckily the mad minds at American Expedition Vehicles have a new big brake kit for TJs and YJs that will have you pulling the reins on your rig much quicker than ever before. Plus the installation is so easy we had our test rig outfitted in a long evening after work and were doing brake tests before bedtime.
1. Here is the new 13.2-inch...
1. Here is the new 13.2-inch brake rotor next to the stock 11-inch version. The new rotor has both the 5-on-5 1/2 and the 5-on-4 1/2 bolt pattern. It may look like an optical illusion, but it's not. The new rotors really are that much bigger.
2. The install is pretty easy....
2. The install is pretty easy. First, all the stock Dana 30 or TJ Rubicon Dana 44 brakes, rotors, and unit-bearings get removed.
3. Next, remove the steering...
3. Next, remove the steering from the knuckles. Hitting the knuckle rather than the tie-rod end itself will quickly loosen the joint. Older rusty parts may require some penetrating oil, a big hammer, or the replacement of the tie-rod ends.
4. The old knuckles come off...
4. The old knuckles come off next. Removing the axleshafts helps but can also allow the gear lube to leak out the axletube. Jack up the side you are working on higher so the lube stays in, or drain and replace the lube at this time.
5. The new American-made cast...
5. The new American-made cast nodular iron knuckle bolts in place of the factory knuckle but has mounting points for the new bigger calipers...
...A high-steer crossover...
...A high-steer crossover steering version is also being considered for development.
6. The original ABS sensor...
6. The original ABS sensor and unit bearing bolts right back into place, or if your Jeep is high-mileage you might choose to replace them at this point. There is a small ring spacer to help center the bigger rotor.
7. The new calipers are two-piston...
7. The new calipers are two-piston versus the stock single piston. They offer 40 percent more surface area for additional stopping power but use off-the-shelf Dodge Ram 1500 pads. You will, however, need 17-inch wheels to cover your new stopping power.
8. Finally, simply bench-bleed...
8. Finally, simply bench-bleed and install the new larger capacity master cylinder, and then rebleed your brakes. (Most auto parts stores have a bench bleeding kit.) AEV has seen stopping distances reduced from 176 to 150 feet with the big brake kit, and that's with Jeep TJ Unlimited running 35-inch tires, a winch bumper, and a 4.0L engine.