Rear Disc Brake Conversion

(w/o Parking Brake)

We now offer a disc brake kit for your 4WD Pickup and 4Runner! We had three goals in mind. It had to be strong, easy to install, and a complete kit. We think as you read on you will agree that all three goals were met and exceeded. To start off with a 3/8" CNC laser cut caliper bracket and we supply grade 10.9 bolts. We used the larger GM style calipers that are shipped fully loaded and we included GM style vented rotors that were custom made just for this application. The DOT approved brake lines are made so that one end fits the GM calipers and the other end attaches to your OEM Toyota brake lines, so no new fittings are required. This kit does require either a 2 lb. residual valve or the ever popular 1" bore master cylinder that most pick ups and 4Runners have already upgraded. The 1" bore master cylinder is not included in the kit since most trucks and 4Runners have already upgraded to this master cylinder.

NOTE: Not DOT Approved, Off Highway Use Only. This kit will not work with OEM Factory Original 15" Wheels. The use of a 1" wheel spacer will be required for factory wheels with a backset over 2 1/2" deep. This kit does not have any type of parking brake with it. We offer a Mechanical Line Lock option, though it should not be used as a parking brake if the vehicle is to be left unattended. Line locks can have a short bleed off time, it should be used to stop briefly on a trail or to set a wheel chock in place, see Part #: 1055435, or a T-Case Parking Brake Kit, see Part #: 1055480.

Contact our Tech Support Line for further information at 928-575-2174.

Note: Images are for illustration purposes only. Images may not represent the product listed. Please contact customer service with any questions or concerns: 1-928-505-2501.

1979-1980 20R 2.2L Pickup 4X4

1981-1995 22R 2.4L Pickup 4X4

1981-1995 22R 2.4L 4Runner 4X4

1983-1995 22RE 2.4L Pickup 4X4

1983-1995 22RE 2.4L 4Runner 4X4

1985-1987 22RET 2.4L Pickup 4X4

1985-1987 22RET 2.4L 4Runner 4X4

1988-1995 3VZ 3.0L Pickup 4X4

1988-1995 3VZ 3.0L 4Runner 4X4

To open a printable PDF version of this instruction CLICK HERE

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.

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



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



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.



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



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.



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.



9. Install c-clip securely into groove. Take care to ensure that c-clip is completely seated in the groove.



9. Continued



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.



11. Install axle assembly into the axle housing.



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.



13. Install one M10x35mm bolt in the remaining hole on each side. Torque all M10 bolts to 45-50 ft-lbs.



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.



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.



15. Continued



16. Install brake lines in the factory “Tee” mounted on the axle and secure the lines to the axle.



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.