726.0chevelle

iTrader: (17)

does anybody know right off hand if a 02 2500hd 2wd and 4wd rear end are different widths? If so whats the difference? I wasnt contemplating the swap until I found a sweet deal on a 4.10 rear today.

malibudave

2500HD should be the same width, but I am not 100% sure. That rear should not be a 9.5". It should be a 10.5" full float rear.

malibudave

Sorry for the pics. They were taken from my iphone while the housing was laying on the concrete floor.

Here is a picture of the passenger side axle flange (front of housing is pointing to the right). The spring perches are sitting parallel to the ground. Notice how the trapzoid shape of the flange is cocked up the the back and down in the front. The driver side is just the opposite, down in back and up in the front.



Here is a pic of the brake adapter I had made. It's 3/8" thick.



Here is a picture of the adapter "mounted" to the axle flange. I orientated the adapter so that the top of the adapter ran horizontal to the spring perch.



I hope this answers some of your guys questions on how this will work. Some of you may think this is overkill, but it allow 6 lug disc conversion or a 6 lug drum conversion on a 2001 and up 1500HD 9.5" SF axle with the brake components located in the stock location. It should also allow disc conversion on 9.5" SF axles that came with drum brakes (this would be an even easier swap). Let me know if you have additional questions.

1FastBrick

iTrader: (17)

Do you have another spacer to go inside the brake backing plate bracket to take up the difference in the void??? You said the flange you had made was 3/8 of an inch thick and that you would need a total of 1 inch thickness.

Sorry only picture I can come with right now of the bracket.

EDIT: Found one of my old post that has pictures of the bracket I made installed in the factory disc brake bracket with shield. The cavity is nearly 3/4 of an inch thick. See post #37
https://www.performancetrucks.net/fo...5/#post4569298

malibudave

The void difference is taken up by the width of a 1/2" nut witch is 5/8" thick. That will give you a total of 1" to space out your bracket.

This is how I see it going together.

After all the holes are drilled into the trapzoid shape axle flange, the 1/2" bolts are inserted from the back of the axle flange. The 3/8" adapter is slide over those bolts and bolted to the axle flange with the 5/8" thick 1/2" size nut. Slide the disc brake bracket over the bolts and seat it against the 1/2" nuts. Use another 1/2" nut to secure the disc brake braket to the axle housing. The length of the bolts used should be determined by the thickness of each item.

Axle Flange - 0.500" I think, it may be more or less.
Adapter Plate - 0.375"
1/2" Nut - 0.625"
Thickness of the dic brake braket - 0.750"
Additional 1/2" nut - 0.625"

The total thickness above is 2.250 inches. You would need at least a 2.500 inch long bolt to bolt all of the disc brake hardware together. If using drum brakes (2005 silverado and up), the thickness of the backing plate is rougly 1/16 of an inch. A shorter 1/2" bolt can be used in a drum brake application.

Items needed for this to work.
Custom adapter plate
4 - 1/2" bolts
8 - 1/2" nuts

If you can see the picture of the adapter "mounted" to the flange, there is no axle flange to bolt to on the bottom bolt hole. The head of the bolt will have to be modified to clear the flange and will only be used to secure the disc brake braket to the adapter. The three other bolts will have to be used to secure the disc brake braket and adapter plate to the axle flange. Because of the width of the disc brake bracket, it also look like you will not be able to use one of the other four bolt holes in the adapter to secure the adapter to the axle flange. It shouldn't matter because 3 bolts should be enough to secure the disc brake braket to the axle flange.

1FastBrick

iTrader: (17)

Thanks for the quick response!!! That makes perfect since now. I hope you get some time to finish your swap. Can't wait to see the finished result.

About20ninj45

Sorry for digging up an old thread but what ever came off this?

malibudave

Just saw this.

Sorry to say, I ended up selling the rear. I lost my 05 CC in the "Great Flood of 2017", so I didn't get to complete the project.