Guys, I finally got around to that disc brake conversion on the front axle of Triple X. This is a really slick conversion, completed for under $300.00.  I need to thank Brennan Metcalf for his technical support on the design, and for some key parts.  Brennan did give me permission to post this information, and it is important that you guys know he makes and sells the backing plates and spacers that you will need.  You can find him at Brennanmetcalf@gmail.com, he also has an online store on Facebook.

Parts List:
1995 or earlier Geo Tracker, Suzuki Sidekick is the donor vehicle, all parts were new from NAPA except those from Brennan and some bolts from Fastenal
Rotor 1992 Tracker P/N4886008 $23.99 EA
Caliper 1992 Tracker - Left SE1764A Right SE1763A - $39.99 EA
Pads SS7305 - $33.99 set
Backing plate/Support Bracket from Brennan $50.00
Bolts 11114852 or 4851, one is longer than the other, I bought both as I was not sure which I would need, they were about $4.00 each delivered.
Brake Hose UP 380280 - $8.11 Each

Step one
Remove the hub and backing plate and old  brake system, remove lug bolts from the hub and drum assembly, and install the lug bolts directly into the front hub.  Install the support bracket from Brennan, I clocked mine to the 2 oclock position on the driver side, 10 oclock on the passenger side.  This way it cleared the shocks and steering gear.

Next step,
The rotors go over the hub so you have to drill out the bolt holes in the rotor as they are just a tad too small, I used a 39/64th drill bit and an a hand drill, worked good.  I also found that the lug bolts protrude through the hub and interfere with the rotor setting flat on the hub.  So I counter sunk the lug bolt holes on the back side of the rotor.  I also took this opportunity to change all my lug bolts to right hand bolts.  Just because.

Next step was to assemble the caliper onto the rotor, and that was just assembly work, it was pretty straight forward.  I did use the 5/16 shims that Brennan provided in order to get the right alignment on the rotor and caliper.  Caliper is mounted to the bracket with M12 1.25 pitch 30mm bolts 10.9 class.  I used the 30mm as I had to use the shims and the locktite 243 blue. Without the shims you could probably get away with  the 25mm bolts. 

Pictures are out of order, but you can see the final assembly first, after bleeding the brakes took it for a drive and it makes a big difference in stopping.  I'm pleased, its really affordable, not cutting or grinding and its completely reversable if you want to go back to the OEM version.
Thanks again to Brennan for all his Help.  I'll be sending him a link to this post so he can chime in with advise and corrections.
Gun

Correct, I did not do anything with the master, although a dual cylinder master might be a good add, it seems as though the system works well with the OE master.  I did not do anything with the steel brake lines, but the brake hoses are not OE, they are from a GMC pickup.  But they did fit right up, no issues.  On some of these conversions I've seen where the guys removed the brake line guards. I left mine on as they did not seem to pose a problem, also I did not what to have to make shims for those two bolts.  The guard bolts also hold the top of the king pin bearing cones in place and I believe the longer bolts would bottom out without the guards or a shim.  We'll see, maybe thats the next project?

Randy,
Yes, the kit for the caliper had the banjo bolts and crush washers needed to go to the caliper and the other end of the line bolted right up to my steel brake lines on the axle.

What wheels are you using?

I just read on another thread that the 16" stock wheels will not fit over this modification. Is that true or can you confirm that the stock wheels will fit?

Dave W.

Thanks for that great info and pictures to show along with the description. I will have to look at what I have and see if it will work for what I have.

Did you do a conversion in the back using the same geo tracker/suzuki brakes? I guess I was just assuming that you would/could only do the front for some reason in my head...

Brad Y. wrote on 07/30/18 at 18:11:30:



Yes, I’m working on getting all four corners swapped out. It’s taking slightly longer than expected since I needed to replace all the hard brake lines and needed to find a set of wheels and tires.