9.25 disc with 8.25 parts
This was done with an axle that was laying around with parts I saved for no reason.
first, block the wheels and jack up rear of vehicle. place jack stands either under frame or rear axle assy.
remove axle cover leaving two loose bolts at the 2oclock and 10oclock positions and drain gear oil
rotate carrier with vehicle in neutral to get to the 8mm retainer bolt
remove the 8mm bolt and slide the cross pin out
remove rear drums
push axles inward to release the c-clips.
retrieve c-clips and then pull the axle shafts out carefully as not to damage the seals.
remove ALL brake hardware. brake lines at wheel cylinder, parking brake cables and brake shoes, springs.
remove 4 14mm nuts from backing plate (save these)
remove backing plate.
carefully remove the 4 studs and set aside (new longer studs are recommended)
now the fun....
I used 8.25 disc brakes off my Dakota that I saved after a 9.25 swap with a posi (trac-lok)
remove all hardware from 8.25 backing plates
notice two steel rivets that connect the two backing plate pieces. remove these and separate them.
I have marked this one with a sawzall to show where to cut.
now that its cut you will need to test fit on the back side of the flange and by grinding a 45 degree edge on the insideof the backing plate and smoothing out the weld on the flange you can get it to sit flush on the back side of the flange.
now remember that other piece of the backing plate you removed... go get it, were gonna cut that too.
pay close attention to where I cut this piece as the cut will be hidden and reinforced.
now to install the studs facing the opposite direction
install the first piece like the picture shown
now the first piece we cut a chunk out of goes behind this and is bolted in using the 4 studs and nuts.
from here you can start re assembly. finished product should look like this..
now you will need 8.25 parking brake cables and the rubber brake hoses. you could use a 3/16 compression fitting to tie the rubber and steel lines together.
this is just something I tried and it works. the spacing is correct and there's no need to ask for jeep rotors and drill them or get old Chevy calipers and weld on brackets. this is by far the easiest swap. a little cutting and some grinding leaves you with a disc brake 9.25.
note: not sure if this will accommodate 15" wheels