JT4x4
The Mud Pit => Wrenching => Topic started by: kirksjeep on January 12, 2012, 03:57:15 PM
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Since us YJ guys never had an option for a D44, we have to upgrade to the ford 8.8 rear. With the 8.8 you get disc brakes, which help a little at stopping the bigger tires, but the YJ single diaphram brake booster is a limiting factor. There are few upgrades out there such at using parts for 70's fords or finding a set up out of a 95 (only year that works, very hard to find and expensive) master cylinder and brake booster. I came across the link below that uses a set up out of a TJ. Now I just need to get one off of Ebay (average price $45).
http://www.jeepforum.com/forum/f12/06-tj-booster-mc-my-yj-1177891/ (http://www.jeepforum.com/forum/f12/06-tj-booster-mc-my-yj-1177891/)
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Sinister Fab makes this for a TJ. Maybe it could work on YJ's too?
http://www.sinisterfabworks.com/shop/item.aspx?itemid=57
"This is Made to Fit perfect onto the Power brake booster plunger to make the dodge 99-01 master cylinders work on your Jeep TJ to upgrade your brake system for one ton style calipers."
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I just picked up a brake booster, master cylinder and proportioning valve from an 04 TJ on Ebay for $40 (and free shiping). ;)
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k with my pos i run the stock yj single diaphram booster a a 69 corvette master 89 waggy calipers on all 4 corners with an adjustable propotioning valve to for the rear and all 3/16th line every where it stops on a dime
i did have to jack with the adjusting rod to make them stop as good as they do i went out 2 or 3 full turns
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My parts finnaly arrived today. Too bad I have duty tomorrow, and I in a few days, I leave for a few weeks. :( I am stocking up parts for a weekend of wrenching when I get some time. On the to do sometime list:
Install the Chromo D30 shafts that have been sitting in a box for over a year
Install the Power Steering Cooler
Fix my Onboard air
and now add the Brake Booster and Master Cylinder
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So based on my list of "To Do" items above, this was my last one. I will post this up incase anyone in the future wants to look up this topic. I followed most of the "How to" from the link in the first post with the following changes:
1. The used TJ brake booster/master cylinder combo didn't come with any of the nuts to bolt it to the firewall or to bolt them together. A quick trip to Home Depot with the brake booster in hand and I was set.
2. I used a 2" grade 8 bolt for the adjustment part. I cut the head of the bolt off and used a grinding wheel to make a vertical notch about 3/8" deep. I slid the end of the brake booster rod (previosly cut off) into the notch and made it so it was a tight fit (i.e took some light taps with the hammer to get it in.). When the welding was done it gave more area to weld and came out looking a lot cleaner.
3. The adjustement portion of the install was not very well explained. In short, I got it close and noticed the brake lights were on, so I adjusted the rod lenth until the brake lights went out. I also just used a standard nut, not a nyloc nut since I can't see how it come come loose, and to make adjustments with the assembly installed is hard enough with the tight space under the dash.
4. I re-used the YJ brake lines from the proportioning valve to the master cylinder. I pulled them off, cut the ends off that go to the master cylinder and installed the TJ fittings. I have a double flare tool, but these lines needed the ends to be convex instead of concave. I did a double flare and then put the fitting in the vice and gently used a body hammer to bend the lip and make the right shape. I then used a file to smooth any rough areas and it came out looking ok. I re-used the YJ proportioning valve so I didn't have to take apart more brake lines. With a little flexing of the lines it all worked out.
The result: WOW!!!! The first trip around the block I locked up all four tires on accident since I wasn't used to the power. A big difference, that I should have done a long time ago.