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Old 01-01-2021, 01:09 AM   #1
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Brakes upgrade options

So I just bought a 2000 E150 that has been 4x4 converted using a ujoint kit and a D44 front axle. I was wondering what kind of brake upgrade options are available? It would be really nice to it least do a rear disc conversion and possibly something up front as well. Would it be feasible to just upgrade the entire rear axle assembly with a newer 9.75 rear axle from a salvage yard?
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Old 01-01-2021, 08:31 AM   #2
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Just FYI I bought it as a daily driver/light travel/camping vehicle. It's a very light build and plan on keeping it that way. Not planning on doing any serious off roading or heavy towing I just wanted to be able to deal with a little snow and mud in mountain roads and campsites. The brakes work fine but require more effort than I prefer. I will also be towing a small 5x8 enclosed single axle trailer occasionally so would definitely prefer that little something extra in the brake department.
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Old 01-01-2021, 11:49 AM   #3
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It's possible to get it feel better, it might be as simple as replace the brake fluid and put new brake pads in.


Do ujoint conversions do anything special with the rear axle? Might want to check that before going to a junk yard.
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Old 01-01-2021, 12:40 PM   #4
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You can drop in an '04 through '06 E150 rear axle. Some '07's also, but that was the transition year where they started building them with Dana 60's. My guess is Wagons all got the D60, but early cargos still had the Ford axle.

Also, have you made sure the brake show adjusters are working? You might get some improvement just manually adjusting the star wheels.

Up front, you might be limited to better pads. I'm really happy with the Napa Ultra Premium pads. Anything ceramic is worse when cold. Tried it once, and almost went through the first stop sign by my house on a cold morning.
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Old 01-02-2021, 09:17 AM   #5
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Thanks for the replies. I'm still in process of driving it home to NW Arkansas Cromer Bozeman, MT so will have to wait toll I get home to fiddle with it. Of course I will try everything I can to make sure what I have is functioning as good as possible. Will start with making sure the tears are properly adjusted and possibly flushing the lines wjth fresh brake fluid.


Cairingb did the 04-06 van's come with rear discs? Do you know what the axle code would be?
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Old 01-02-2021, 10:02 AM   #6
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Yup, those were the E150 years with rear discs, pre-8500+ GVWR. I don't know the axle codes however.

Also keep in mind that when you swap-in rear discs, you'll need to swap the M/C too.
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Old 01-03-2021, 01:53 PM   #7
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So that is basically the same axle I have now but with disc brakes? Hopefully that means the driveshaft should bolt right up?
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Old 01-03-2021, 01:55 PM   #8
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Good point on the m/c. I was wondering if that would be an issue since there is considerable difference in piston area with the disc calipers.
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Old 01-03-2021, 03:42 PM   #9
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So is this an 8.8? Looks beefier than I remember one of those looking like.
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Old 01-03-2021, 03:42 PM   #10
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Yup on the axle being the same. No major differences until the E150 got bumper to 8500 GVWR in 2007. That's when it gained the same 35-spline Dana 60 from the E350 (which also changed ABS systems).
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