Toyota Landcruiser
Rear Brake Upgrade
Package
HOPPERS STOPPERS
9 Nevada Ct
Hoppers Crossing Vic 3029
Ph 03 97486950
Fax 03 97485965
Email hopstop@hoppers.com.au
Web www.hoppers.com.au
HOPPERS STOPPERS
Rear Brake
Upgrade
Package
78/79 Series
Toyota
Landcruiser
Introduction
Toyota Landcruiser 78/79 Series Vehicles are used extensively
throughout the country, and in particular, are favoured by mining
operators, many in underground use where conditions are
extreme.
Whilst the basic vehicle is well respected by the industry, the rear
disc brake arrangement has proven to be inadequate for the
conditions, with the rear brake pads and hand brake both
exhibiting accelerated wear way beyond the rest of the vehicle.
In worst conditions, the rear brake linings will wear to the metal
backing plates in a matter of weeks, resulting in total loss of rear
brakes with accompanying work safety concerns. Handbrakes
often fail to hold with days.
HOPPERS STOPPERS
There may have been reasons for this design, but it seems to
have been a retrograde step when subjected to regular immersion
in muddy and highly corrosive environments.
There seem to have been several compromises needed to arrive
at this design.
Rear Brake
Upgrade
Package
78/79 Series
Toyota
Landcruiser
HOPPERS STOPPERS
1 Rotors
Being a full floating rear hub and axle design, restricts the
inside diameter of the rotor face, particularly when we try to
retain the simple loose fit "slip on" design.
In order to achieve a suitably larger swept area, it is therefore
better to attach the rotor from the inside in the same manner as
the front arrangement.
This will require the hub to be removed from the axle housing
for disc fitment; this is not a big job and in any case allows
repacking of the bearings.
In order to facilitate the original conversion, 5 counter sunk
holes need to be drilled on the rear carrier hubs, either at the
mine's workshop or as a change over supplied by Hoppers
Stoppers.
The end result is a 300mm diameter rotor; 28mm thick
compared to the original 18mm thick and almost double the
swept area.
No other alterations are required and all standard bearings and
seals are retained, with the ability to convert back to the
original design if desired, say at time of trading in the vehicle.
HOPPERS STOPPERS
Hoppers
Stoppers
Rear Brake
Design
78/79 Series
Toyota
Landcruiser
2 Caliper Design
Within the automotive industry, all common rear calipers are
much smaller than the front with usually much smaller pad
area.
Brake balance considerations dictate much smaller rear
hydraulic piston areas, essentially meaning that there is no
readily available alternative rear caliper that offers a solution.
We therefore achieve our desired large pad area and thick
rotor requirements by sleeving an Australian made front caliper
down to smaller bore piston of suitable diameter.
3 Brake Pads
As the base calipers are originally for the front of a locally
made vehicle, the pads are available in many material options.
Brake torque applied by a caliper to a rotor is proportional to
the hydraulic area and does not change with pad area.
It is therefore possible to reduce the specific load on the pad,
greatly reduce wear rate and still have correct brake torque.
4 Attachment
Caliper mounting to the axle housing is via a 12mm thick steel
plate attached to the original backing plate holes using original
size 4 off 12mm bolts.
For comparison, the original caliper attaches to a 5mm plate.
The new caliper cradle attaches to this using 2 off 12mm bolts,
which are the same size as original Toyota rear caliper usage.
HOPPERS STOPPERS
Hoppers
Stoppers
Rear Brake
Design
78/79 Series
Toyota
Landcruiser
5 Handbrake
To attach a suitable "tail shaft disc" we arrange a 10mm thick
carrier plate to be sandwiched between the output flange and
the universal joint yolk.
This requires a small and acceptable movement of the slip joint
at the front of the tail shaft.
Before
After
Summary
Hoppers Stoppers rear brake upgrade design principle is based
on the fact that known acceptable front brake performance is
repeatable at the rear.
The basic vehicle remains unmodified in every aspect with
existing brake master cylinder and piping, wheels, hubs, gearbox
and such kept in standard condition.
Handbrake
From Inside
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