8.8 E-BRAKE solution

[jbolty]

Just finished my 8.8 swap. No real surprises here, spring under so I was able to use the flexible brake lines that came with the explorer axle. Had to fab a couple of brackets to hold the soft lines in place.

The real issue was the e-brake. I searched all over the place for a good way to do it and it seemed that there were a million good ideas, a few expensive ones and a few bad ones. What I ended up with is so simple that I can't believe that no one has posted it before.

First. When I pulled my donor axle at the junkyard I was able to get the full set of ebrake cables and the soft line with it. Without that this would be more of a challenge, or more costly.


1. Cut the existing 8.8 cable housings to be the same length as the former D35 cables. I used an angle grinder for this, very carefully so as not to cut the inner cable. A hacksaw would work too, but I am not that patient. Do not cut with pliers, or anything that will crimp the cable.


http://i3.photobucket.com/albums/y95/jeffboulton/jeep/88/HPIM0748_sm.jpg

2. Put a 3/8 hose barb on the end of each cable, as shown. Was a perfect snug fit.

http://i3.photobucket.com/albums/y95/jeffboulton/jeep/88/HPIM0749_sm.jpg

3. I later added a piece of hose to the end of each barb to stop them from rattling, but it is probably not needed. After it is tightend up there will be no rattle.

http://i3.photobucket.com/albums/y95/jeffboulton/jeep/88/HPIM0751_sm.jpg

4. Slide the cable ends into the existing e-brake cable bracket.

http://i3.photobucket.com/albums/y95/jeffboulton/jeep/88/HPIM0752_sm.jpg

5. cut the extra end of the cables so they are long enough to reach the adjuster and a little past. Used the grinder here too, got a nice clean cut.
Slide on a pair of cable stops and tighten them down good and snug. Make sure they are even so there will be a straight and even pull on the adjuster.

http://i3.photobucket.com/albums/y95/jeffboulton/jeep/88/HPIM0753_sm.jpg

6. Then side in the cable that comes from the pedal and adjust as needed. I added an extra spring because my main cable has a little kink that keeps the pedal rfom coming all the way back up. This spring fixes that.

http://i3.photobucket.com/albums/y95/jeffboulton/jeep/88/HPIM0754_sm.jpg

That's it.

Here are a couple of pictures of my hard lines and my snazzy new Ruff Stuff diff cover.

http://i3.photobucket.com/albums/y95/jeffboulton/jeep/88/leftside_sm.jpg


http://i3.photobucket.com/albums/y95/jeffboulton/jeep/88/rightside_sm.jpg

http://i3.photobucket.com/albums/y95/jeffboulton/jeep/88/ruff_stuff_cover.jpg

[1BusyBoy]

Sweet Nice work........................

[sinbad]

I see u are using the 8.8 u bolt plates. They will hang up on rocks baddly. Dont ask how i know. I used my 35 plates on the u bolts. as a temp shock mount I welded some bolts to the axle tube to mount the shocks to, works great.
Oyea, I used the factory cables and loped them on the ebrake arm with some cable u bolts
Nice work on your cables

[JeeperDon]

I found the 8.8 parking brake was pretty useless on large tires, even if set up right. I went with this at the output of the t-case. The 4.88 gears now multiply the force.

http://www.hv4w.org/DonsForumPix/disc_e-brake1.jpg

[jbolty]

I see u are using the 8.8 u bolt plates. They will hang up on rocks baddly. Dont ask how i know. I used my 35 plates on the u bolts. as a temp shock mount I welded some bolts to the axle tube to mount the shocks to, works great.
Oyea, I used the factory cables and loped them on the ebrake arm with some cable u bolts
Nice work on your cables



I am not really happy with the bottom plates. I had to use them as a temp solution untill I could get proper shock mounting tabs. The ones I bought were meant for SOA and I did not notice until I was commited to the job.

thx