Novak Conversions Jeep Wrangler TJ engine mounts

2025 ROTY big brake install and review

John Cooper

John Cooper

Twilight Zone
Original poster
Supporting Member
Ride of the Month Winner
Joined
Jun 10, 2020
Messages
8,706
Location
Bryant, AL.
I was fortunate enough to win the 2025 ROTY, and again want to thank the sponsors @mrblaine @Wranglerfix and @Shawn at Tom Wood's for their support of our community.

I received the Black Magic Brake kit last Friday, put the Jeep up on Jackstands and sprayed all the bolts and nuts down with Croil. Then started to wait on warmer temperatures to move in.

I know we have all heard of Blaines packing skills but until you experience it, you really just don't know how good it is.
 
Last edited:
  • Like
  • USA Proud
Reactions: ColoJeep, mrblaine, chili_pepper and 2 others
Saturday I took both boxes to the shop and put everything on the work table.
20260117_150627.jpg


Then brought the BMB instructions book back to the house. Let me insert here, every Jeep parts supplier/manufacturer could learn a thing or two from Blaine on this.

I probably read through the instructions 4-5 times to be sure I understood and was extra familiar with them.

20260116_162232~2.jpg
 
Tuesday afternoon I went to the shop heater, moved it close to the work area and started the tear down.

Sorry for the lack of pictures here but it's straight forward taking everything off, and Kroil is your friend.

20260120_151418.jpg


20260120_151834.jpg
 
  • Like
Reactions: Wildman and TheBoogieman
Pictures will be a mixture of passenger and drivers side due to me getting focused on the job.

Once everything was taken apart I took a wire brush to the Inner C's to clean them up and start the install.

20260121_121943.jpg

20260121_122018.jpg

20260121_143801.jpg
 
  • Like
Reactions: Wildman and TheBoogieman
Once you get the axles installed, the hardest part of the job for me is next.

You have to grind the unit bearings down to fit into the rotor hat, what makes it hard for me is I have essential tremors and it makes doing fine lines and stuff almost impossible.

After I finished the grinding I thought why didn't you make a template dummy 🤣 🤣
 
  • Like
Reactions: Wildman, PG. and NashvilleTJ
Now @mrblaine sends you everything you need including his brake lockout tool for bleeding the brakes, but I have a piece of clear tube that I use to gravity bleed mine with because I have no ABS.

New Banjo bolts and washers.
20260122_120250.jpg


New caliper saddle bolts and a tube of red locktite.

I'm going to start the break in procedure today and will keep this updated as I go.
 
  • Like
Reactions: ColoJeep, Wildman, lBasket and 2 others
I just want to add.

Blaines instructions are straight forward and easy to follow, if you read them and follow them you really should have no reason to call him, that's how complete they are, and he even includes photos for dummies like me.

Edit:

Blaine sent me a DM asking all the questions he needed answered, which i did, I was thinking the 15" kit and he said the 16" should work.

I told him I trusted his judgment because he knows this stuff inside and out, that's the honest truth!!!!!!!
 
  • Like
Reactions: Wildman, Weasellee, lBasket and 3 others
I just installed the kit as well between Christmas and New Years and couldn't agree more on the level of detail in the kit. Packaging, instructions & content is top notch. Had the same conversation with Blaine about 15" vs 16" rotors because I have 15" wheels and he said 16" rotors should fit with my back spacing so I trusted him as well and everything fit like a glove.

I peppered Blaine with a bunch of rookie and some non-brake related questions and he answered everyone of them within a few hours. Can't imagine how many emails, DM's and phone calls he gets everyday and still do his day job.

I unfortunately live in Michigan and between the snow and deep freeze, I probably won't be able to do the break-in for another month or so.
 
  • Like
Reactions: Unique Username, John Cooper, lBasket and 2 others
StimpsonJCatt said:
I just installed the kit as well between Christmas and New Years and couldn't agree more on the level of detail in the kit. Packaging, instructions & content is top notch. Had the same conversation with Blaine about 15" vs 16" rotors because I have 15" wheels and he said 16" rotors should fit with my back spacing so I trusted him as well and everything fit like a glove.

I peppered Blaine with a bunch of rookie and some non-brake related questions and he answered everyone of them within a few hours. Can't imagine how many emails, DM's and phone calls he gets everyday and still do his day job.

I unfortunately live in Michigan and between the snow and deep freeze, I probably won't be able to do the break-in for another month or so.
Click to expand...

We are expecting an ice storm this weekend, hopefully it will miss us.

I'm hoping to start the breakin today when I go to the grocery store shortly.

Blaine has answered my phone calls in the past on a brake question we couldn't figure out where I used to work.

Not many will do that.
 
  • Like
Reactions: ColoJeep, Wildman, Weasellee and 1 other person
John Cooper said:
Once you get the axles installed, the hardest part of the job for me is next.

You have to grind the unit bearings down to fit into the rotor hat, what makes it hard for me is I have essential tremors and it makes doing fine lines and stuff almost impossible.

After I finished the grinding I thought why didn't you make a template dummy 🤣 🤣
Click to expand...
You have a template laying next to you on the floor. Use the rotor, when it fits, stop grinding. If it doesn't, keep grinding. You really aren't going to overgrind it and so what if you do?
 
  • Like
Reactions: ColoJeep, Unique Username, Apparition and 2 others
John Cooper said:
Test fit the rotors and used 2 lug nuts to secure the rotor in place. View attachment 668108
Click to expand...
The biggest issue is grinding exactly to the ID of the rotor hat and leaving a sharp corner. If you pull the rotor and look at there the rotor hat wall meets the hat section for the lug studs, there is a small radius to prevent a stress riser. The sharp corner of the flange makes contact and causes the rotor to wobble.
 
  • Like
Reactions: ColoJeep and John Cooper
John Cooper said:
Now @mrblaine sends you everything you need including his brake lockout tool for bleeding the brakes, but I have a piece of clear tube that I use to gravity bleed mine with because I have no ABS.
Click to expand...
To clarify, the lock out tool has nothing to do with ABS. It is simply to lock out the ability of the shuttle valve to shift under differential pressure. Jeep changed the spring pressure or the detent which allows the shuttle to shift easier during a manual bleed. I would encourage you to get a helper to do a manual bleed and then go back the next day and do a 1-2 pump per corner bleed to get the rest of the air out.
John Cooper said:
New Banjo bolts and washers.
View attachment 668114

New caliper saddle bolts and a tube of red locktite.

I'm going to start the break in procedure today and will keep this updated as I go.
Click to expand...
Do the break in with enthusiasm. You are pushing on the pedal hard enough to try and lock them up at each stop. Don't keep them locked up, but that's how hard you should be stopping. Don't be shy.
 
  • Like
  • Love
  • USA Proud
Reactions: ColoJeep, speeding_infraction, John Cooper and 1 other person
John Cooper said:
I just want to add.

Blaines instructions are straight forward and easy to follow, if you read them and follow them you really should have no reason to call him, that's how complete they are, and he even includes photos for dummies like me.

Edit:

Blaine sent me a DM asking all the questions he needed answered, which i did, I was thinking the 15" kit and he said the 16" should work.

I told him I trusted his judgment because he knows this stuff inside and out, that's the honest truth!!!!!!!
Click to expand...
It isn't an issue of judgement. If the 16 didn't fit, that would be a good exercise to show folks how easily the problem is solved by simply switching rotors and converting the 16" to the 15".
 
  • USA Proud
  • Like
Reactions: speeding_infraction and John Cooper
Novak Conversions Jeep Wrangler TJ engine mounts
Top Bottom