Brake issue! !!

You guys haven't helped me immensely thank you LKNxj! I'm looking forward to making this happen as my Jeep sits....

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No I don't have a master cylinder I was just wondering what the MS part of your text was...

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Oops. MS = master cylinder. I musta been hitting the Makers Mark by that time, lol
 
I hope to be doing this swap in the next couple of months. If you beat me to it, please post up your results and challenges. I'll do the same. I have a 91 so I'm interested about the previous comment about the brake switch mentioned just above about the 91 specifically.


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Ahh, Some info!

So I went to O'Reilly's today and had them bring a '95 - '96 and a '97 - '01 power brake booster up to the counter and I measured them. The difference in the measurement of the booster shaft, from the firewall mounting surface to the center of the hole that attaches to the brake pedal assembly is:

1995-1996= 5 3/8"
1997-2001= 6 1/8"

The '97 - '01 is 3/4" longer than the '95-'96.

I feel better knowing that.
 
Good to know warlock good thinking .so 95,96 is what I want? does anyone know the bore size .?because when looking up at RockAuto they had different bore sizes I guess I could just wait till I pulled the old system out

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Here's a write up on it for a MJ. I may have some of the facts wrong, I looked it up when some months ago when I couldn't get ours brakes feeling right.

http://www.fourwheeler.com/how-to/transmission-drivetrain/154-0810-cheap-jeep-brake-system-upgrades/


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Good to know warlock good thinking .so 95,96is what I want? does anyone know the bore size .?because when looking up at RockAuto they had different bore sizes I guess I could just wait till I pulled the old system out

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Good to know warlock good thinking .so 95,96 is what I want? does anyone know the bore size .?because when looking up at RockAuto they had different bore sizes I guess I could just wait till I pulled the old system out

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The master cylinder you want is for 1995 - 2001 XJ. Those years all used the same master cylinder. 1" bore. And it bolts up to the '95 - '96 power brake booster which is also the one that you want.

If you go to a smaller bore master cylinder, it will not push enough fluid. If you go with a larger bore than 1", it will move too much fluid and the pedal will be harder to push and you will lose the advantage of the better braking.
 
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I think the master is the same 95 up for a lot of jeep applications.
It's the booster that is unique to 95-96 and a perfect fit with out much modding.

You really not changing much in the brake hydraulic system works, you're still running the same calipers and same size lines. It's the booster that makes a huge improvement.

Well, Guess if you're getting rid of the abs it is a lot different.


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The master cylinder you want is for 1995 - 2001 XJ. Those years all used the same master cylinder. 1" bore. And it bolts up to the '95 - '96 power brake booster which is also the one that you want.

If you go to a smaller bore master cylinder, it will not push enough fluid. If you go with a larger bore than 1", it will move too much fluid and the pedal will be harder to push and you will lose the advantage of the better braking.

You have me wondering if my never solved problem with 87 Wagoneer's mushy peddle is the wrong MC Wrong piston size?). I discovered the wrong brake booster from the PO on my 89 that was causing brake light switch issues and found issues with the 2.5 L, 85 brake booster size difference over the counter.
 
I doubt it. Wait was that the one where you couldn't find a better brand rebuilt? My be thinking of someone else

But I do think this upgrade is a great idea, just picked up a WJ booster & master for which ever jeep needs it first. I think it'd fix the mushy peddle. Oddly it has always been the 85 jeep with the brakes that felt good, especially after the ford 8.8 w/disc brake up grade


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The master cylinder you want is for 1995 - 2001 XJ. Those years all used the same master cylinder. 1" bore. And it bolts up to the '95 - '96 power brake booster which is also the one that you want.

If you go to a smaller bore master cylinder, it will not push enough fluid. If you go with a larger bore than 1", it will move too much fluid and the pedal will be harder to push and you will lose the advantage of the better braking.

Keep in mind that when I typed that, I was referring to a stock XJ brake system, disk front and drum rear. It even works good for the WJ front disk upgrade. We'll see how it goes when I go to the rear disk setup, Eldorado calipers. From what I've read, it should be fine for that also. We'll see...
 
You have me wondering if my never solved problem with 87 Wagoneer's mushy peddle is the wrong MC Wrong piston size?). I discovered the wrong brake booster from the PO on my 89 that was causing brake light switch issues and found issues with the 2.5 L, 85 brake booster size difference over the counter.

Yea, it could be that the master cylinder bore size might be too small.
 
Thanks for that info it makes sense on that note I just looked up Crown Automotive and it looks like they have a brake conversion for my setup one of them is 1 1/8 and one is one 1 inch bore, they have two different ones one is for aftermarket axles and one is for stock axles I don't understand the difference. I have stock axles but I do have bigger tires planning on getting a regeared?

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Well hell I think I'm going to be going to the junkyard soon, my HEEP is not feeling too good just sitting in the driveway! Thanks for all the help peeps! I love this I love this forum it is very informative for sure!

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Btw you should by fine with bigger tires with this mod. A bunch with bigger tires will swear by it.
If you start to go extremely maybe revisit it but it should be fine for everything else


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I sure hope so cuz I'm running 33-12 50 now and it doesn't break the best so in the next week or so I'm a do this modification I will let everybody know how it went thanks. Pez

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There was a guy with 33 maybe it was 35 talking of the brakes slamming it to a stop in the conversion thread.

I wish I had done this upgrade when the master went out not long ago, but we needed the jeep back quick cause her car was not working.

As big a pain bleeding the brakes and replacing the line turned out to be this swap might have been easier.


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