Part # 1055202 – Rear Disc Brake Conversion (1979-1995) 4wd Pickup & 4Runner

To open a printable PDF version of this instruction CLICK HERE
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Tools Needed:

  • ⅜” & ½” Ratchets
  • ⅜” Allen sockets, 17mm, 19mm, 21mm Sockets
  • 10mm, 11mm, 12mm, 14mm, 17mm Wrenches
  • Hammer
  • Floor Jack and Jack Stands



  • Torque Wrench
  • Press
  • Bearing Puller
  • Seal Puller
  • Brake Fluid (DOT 3)

Installation Notes:

    1. Read all instructions completely and carefully before you begin.

    2. Check to make sure the kit is complete and that no parts are missing. If anything is missing, please contact Trail-Gear at (559) 252-4950.

    3. Park vehicle on a clean, dry, at, level surface and block the tires so the vehicle can not roll in either direction.
NOTE: This installation removes your factory emergency brake. We strongly recommend installing an aftermarket e-brake or line lock.

Installation Instructions:

1. Jack up the rear of your vehicle, secure it on jack stands, remove the wheels, and drums from your vehicle.

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2. Disconnect the brake lines (10mm) and the e-brake cables.


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3. Remove the 4 nuts holding bearing pocket in place on each side.

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4. Slide the axle assemblies out of the housing. A small amount of gear oil may leak from the housing, so have a oil pan ready to catch the fluid.
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5. If you are installing new Trail-Gear chromoly axles, bearing pockets and bearings, skip to step 7. If you are reusing your axle shafts, bearings, and bearing pockets, remove the bearing retaining ring from the axle.

6. The drum brake assembly and backing plate should be removed with a press and a bearing puller according to your Toyota owners manual. If you do not have the correct tools or mechanical experience to complete this step we advise that you find a qualified automotive shop or an authorized Trail-Gear installer to complete this step for you in a safe and professional manner. If you have any questions about this step, please call Trail-Gear tech support at (559)252-4950
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7. Press out the 4 studs holding the bearing pocket to the backing plate. Remove the old bearing and seal from the bearing pocket if you plan on installing new ones.
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8. Install new seal and bearing in the bearing pocket and using a press, install the assembly on the axle. Install the bearing spacer and the snap ring on axle.
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9. Install c-clip securely into groove. Take care to ensure that c-clip is completely seated in the groove.
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9. Continued

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10. If you are installing new seals (recommended), remove the old o-ring from the axle housing and install new o-ring seal and oil seal.
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11. Install axle assembly into the axle housing.


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12. Using 3-M10x40mm bolts (per side), install the brake caliper bracket on the back side of the axle flange. The bracket needs to be clocked to the 2 o’clock position, or above the axle to the rear of the vehicle. The brake line enters the caliper from the bottom and the bleeder is on the top on both sides of the vehicle.
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13. Install one M10x35mm bolt in the remaining hole on each side. Torque all M10 bolts to 45-50 ft-lbs.





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14. Place rotors over the wheel studs and install the calipers with the special fasteners that are supplied with the caliper. There is a right hand and a left hand caliper. The left side is shown, brake line on the bottom, bleeder on the top. Torque caliper bolts to 30-35 ft-lbs.
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15. Install brake lines in calipers using the banjo bolt and 2 copper washers (1 per side) that were supplied with the caliper. The bend in the fitting needs to be facing up(away from the bolt head) so that the brake line can be routed over the leaf spring and on top of the axle.
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15. Continued

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16. Install brake lines in the factory “Tee” mounted on the axle and secure the lines to the axle.
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17. Install wheels and torque lug nuts.

18. Install brake proportioning valve (Summit # SUM-G3905), residual valve (2 psi) and line lock (Poly Performance # JAMAR-PK1-BN) as required for your application. It is recommended that you install one of our 1”bore master cylinders (TG #140001-1). This will help with the higher volume of fluid required for the rear calipers. It also has a built in 2 psi residual valve which will keep 2 psi of pressure in the system for better pedal response. You can also purchase an in-line 2 psi residual valve to use with your existing master cylinder. For additional tuning, you can install an adjustable brake proportioning valve to adjust the pressure from supplied to rear brakes.

19. Completely bleed brakes so that all air is removed from the system and test for leaks.