How do I modify a TJ axle flange to accept ZJ disc brake backing plate (with ABS)

[TJRD4]

Using the disc brake backing plates and ABS wheel speed sensors from a 97 ZJ on a TJ to convert from drum to disc and maintain my ABS. Cleaned up the old backing plates but see that I may need to modify the axle flange to accept the wheel speed sensor. (it looks like I may need to cut out a half circle between the left two backing plate holes)

Does anyone have a picture of a ZJ axle flange or recommendations on how to modify to accept the wheel speed sensor? Thank you.

 

[DuckNut]

This is a question for the guy at black magic brakes

 

[Rickyd]

I know this doesn't answer your question,but it's pretty easy to delete abs with a line kit and fitting swap on the prop valve,then pull the relay and fuse so you don'tget a dash light. I did that on my 97
Post in thread 'Project Basketcase!' https://wranglertjforum.com/threads/project-basketcase.67755/post-1258270

As to the zj parts, will the sensors plug in and work with your electronics?

Are your Dana 35 tone rings in the right place to function with the zj stuff?

 

[zackcj7]

Using the disc brake backing plates and ABS wheel speed sensors from a 97 ZJ on a TJ to convert from drum to disc and maintain my ABS. Cleaned up the old backing plates but see that I may need to modify the axle flange to accept the wheel speed sensor. (it looks like I may need to cut out a half circle between the left two backing plate holes)

Does anyone have a picture of a ZJ axle flange or recommendations on how to modify to accept the wheel speed sensor? Thank you.

View attachment 595322View attachment 595321

I attempted this when I did my rear swap over 10 years ago. I ended up giving up on making the ABS functional. If you get it working be sure to share the details.

 

[TJRD4]

I attempted this when I did my rear swap over 10 years ago. I ended up giving up on making the ABS functional. If you get it working be sure to share the details.

I know this doesn't answer your question,but it's pretty easy to delete abs with a line kit and fitting swap on the prop valve,then pull the relay and fuse so you don'tget a dash light. I did that on my 97
Post in thread 'Project Basketcase!' https://wranglertjforum.com/threads/project-basketcase.67755/post-1258270

As to the zj parts, will the sensors plug in and work with your electronics?

Are your Dana 35 tone rings in the right place to function with the zj stuff?

Tone rings are the same tooth count; axle shafts same length. The rear sensors use a different form factor than the drums but are still 2 wire. Making up a pigtail adapter for the wiring. They should product be same signal being half effect sensors but will check their outputs compared to the front sensors.

 

[TJRD4]

@mrblaine do you have a picture of an axle flange that would accept the sensor?

 

[mrblaine]

@mrblaine do you have a picture of an axle flange that would accept the sensor?

Not in my pocket, but- if I was doing this, I'd go dig up the shafts from a 95-98 ZJ and find out if they are compatible with your Dana 35. Probably look a fair bit like this-

https://www.ebay.com/sch/i.html?_nk...RQ62vaGHvBoh-w7QmuIBVsOXEt6Pjua0aAoeGEALw_wcB

 

[TJRD4]

Not in my pocket, but- if I was doing this, I'd go dig up the shafts from a 95-98 ZJ and find out if they are compatible with your Dana 35. Probably look a fair bit like this-
View attachment 596049

https://www.ebay.com/sch/i.html?_nk...RQ62vaGHvBoh-w7QmuIBVsOXEt6Pjua0aAoeGEALw_wcB

Yes, they are the same. Same spacing.

 

[mrblaine]

Yes, they are the same. Same spacing.

And?

 

[TJRD4]

Sorry, to clarify, before i went down this rabbit hole I cross referenced the axle shaft part numbers with USA Standard Gear. The part numbers for the rear axle shafts that do not include the tone rings are the same. When you compare the versions with the tone rings the difference is the wheel stud length (longer on the ZJ for the rotors). The wheel speed sensors while a different form factor on the rear, are still the 2 lead style and produce the same ~1.09 k ohm resistance in freespace.

What im trying to figure out is how to modify the axle housing flange to accept the wheel speed sensor wiring. Example below with the white circle on the front leading edge of the flange.

 

[mrblaine]

Sorry, to clarify, before i went down this rabbit hole I cross referenced the axle shaft part numbers with USA Standard Gear. The part numbers for the rear axle shafts that do not include the tone rings are the same. When you compare the versions with the tone rings the difference is the wheel stud length (longer on the ZJ for the rotors). The wheel speed sensors while a different form factor on the rear, are still the 2 lead style and produce the same ~1.09 k ohm resistance in freespace.

What im trying to figure out is how to modify the axle housing flange to accept the wheel speed sensor wiring. Example below with the white circle on the front leading edge of the flange.


View attachment 596062

Everyone always wants to give me massive grief for my high levels of specificity. I read your post a few times and the replies and still did not understand why you wanted to modify an axle flange when you can just buy one for a ZJ. Now I understand you want to modify the axle HOUSING end flange.

Bolt up the backing plate, scribe the hole, remove backing plate, hack out the material inside the scribe.

 

[TJRD4]

Thank you, i figured I would have to grind out a bit of material but was hoping to see a picture of an OEM ZJ axle housing flange for comparison.

 

[Rickyd]

Thank you, i figured I would have to grind out a bit of material but was hoping to see a picture of an OEM ZJ axle housing flange for comparison.

Google is your friend there. Junkyards and measuring equipment even better