Brake issue! !!

So I finally have everything installed and I have a super soft pedal. I did do a bench brake bleed and bled on but still super soft could I be missing something or do I have to take the master cylinder off and adjust the adjusting rod?

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6463966bb97d9390d4630b491fd439e9.jpg
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Also did you start bleeding from the back right wheel and bleed the whole system? If there's no leak in the system and no air in the lines I'm wondering if you're not getting enough travel of the rod. I.e rod length shorter than original system.


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Sorry for three posts - have you tried actually stopping the vehicle with the system yet? The reason I ask is that my dad actually had a 1995 model growing up with this booster system. I was amazed at the difference between pedal feel between my jeep with the Bendix ABS system versus his simple booster set up. The force applied to the pedal to stop the vehicle was dramatically less than the force that I needed to apply for my 1991 jeep. It could be that you're just not used to the efficiency.


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Good morning LKN, just did it in my driveway also when I was bleeding my brakes my left rear brakes did not bleed out.I'm changing out the brake cylinder in that side so maybe it's sucking in air?! The Jeep stops but goes right to the floor pretty much right after.

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Yeah I brought it with me compressor system with a trigger it's a one-man operation but I never seen the lines clear up all the way so I'm thinking the driver rear cylinder that's not working must be sucking in air into the system going to change the cylinder right now will keep you posted

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Okay as of right now are you using everything inside the cab from your jeep, or are you swapping the brake pedal too?


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My guess is air trapped in the system. Also make sure your rear drum brakes are adjusted correctly, this was part of my problem when last time I swapped the brake master. Even then it took a lot of bleeding the system to get all the air open/broken lines let in.

Other than that I would check what LKN_xj says about the pedal travel. If you've got the 95 up booster system you should have soon really good brakes when you're done.


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Agree with Green Mesa. If the swap details are good, that's about the only thing other than a leak. And you would know if you had that.

It's ironic you posted about this today. I just started researching again on this topic last night and plan on starting to rip into mine today.

Green Mesa I have a 91 and my brake light switch looks like the pic posted earlier. I won't have a need to drill out or notch the end of the brake pedal rod to make it work and it doesn't sound like Pezman needed to either.


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Yeah I think the 84-90 have the style where the booster rod (?) has to be machined to accommodate the brake switch and the 91 easily adapt.
As I remember it removing the booster for the 91 was just getting it disconnected from the pedal, the brake switch stayed where it was at .


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Green Mesa XJ said:
Yeah I think the 84-90 have the style where the booster rod (?) has to be machined to accommodate the brake switch and the 91 easily adapt.
As I remember it removing the booster for the 91 was just getting it disconnected from the pedal, the brake switch stayed where it was at .


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Click to expand...



Correct - confirmation from my 91. And wow that's a lot of dog hair.

0bb86653bbada176eec9a4e30c1c7620.jpg



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So here's a new question - I started tearing into mine tonight. I found the location where the rear brake line comes into this POS. Then I found where the right and left front wheels come into the other side of the POS :). But then I noticed something: there's a soft line that turns into a hard line coming out of the bottom of the reservoir that runs all the way to the passenger side behind the engine and connects to this other piece of the system underneath that black plate on the back left of your engine bay. What the heck is this??

Line at the back of the reservoir:

02903de04dfa81156305d4c1c766823c.jpg


Line going into the thing I'm pointing to on the passenger side:

0459afc25552a126c6cd6d1b1b985226.jpg


Whole passenger side:

eb17fd973524fdf149886f93a0705fac.jpg



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Weird I'd say it's a motor for the abs or something.

None of that crap is there in mine (none abs).
In fact that's closer to where the fuel vapor canister.


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Sweet. It's coming out :). It says "warning, high pressure" on the line. I pumped the pedal 50x so I'm gonna start unbolting and see what happens.


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Warlock1 said:
Here is the whole mess (ABS system) after it was pulled out. It's all good if anyone wants it for free. The pump was a little weird but it worked.
20160908_121103.jpg
Click to expand...



Looks like warlock had those pieces

Edit: so did pezman, although it's upside down in his picture


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