RockTracXJ
NAXJA Forum User
- Location
- Colorado Springs
94 XJ, non-ABS, cruise
Finally got around to getting the dual diaphragm booster upgrade done this weekend. I had been looking into it for awhile now (there was some good info here on the forum, the madxj write-up, and cagedxj gave me some info, too), but it took awhile to get the courage up to tie into my brakes like that.
Started on Thurs, pulled the old booster and master cylinder (MC):
In this pic, note the adapter in the proportioning valve (PV) on the right, turns out I didn't need to buy one of the adapters because it was already there. More on the adapters later.
I was told that a TJ booster and MC would work for the XJ so I bought one off of e-bay awhile back. I put it in, but the booster rod was too long. I made up for this by putting some washers on the booster mounting bolts to space it out some from the fire wall and I adjusted the brake light/cruise switch out quite a bit, this in turn caused my brake pedal to be quite a bit higher, which I wasn't to thrilled about. I had meant to get the 8 mm spacer from later model XJs and ZJs? but hadn't been able to, I don't think I would have been able to use it anyway, because the booster bolts weren't very long.
Here is a pic of the light/cruise switch, I had pulled it back in it's hole and bent the mounting plate back to make it work: (dis-regard that booster rod, it's not from the TJ booster)
Here is the TJ booster installed, with the custom bent brake lines.
I drove around with that booster on Friday and part of Saturday and was happy with the increased braking power, but the booster had a small vacuum leak (damnit!) and I didn't like having my pedal so high. I had bought a remanufactured '95 booster and new MC in case the TJ booster didn't work, so I figured I would put that in instead. I had trial fit the booster on Thurs before putting in the TJ booster and it seemed to fit pretty good. The rod was also a bit longer than original (shorter than the TJ, though), and I figured I would try to find the spacer. The reman booster had longer mounting bolts, too. Finding the spacer was a PITA and took all of my Saturday morning, but I finally found one and got it off of an 01 XJ. I recommend getting this spacer for this swap.
Saturday afternoon I pulled the TJ booster and put in the reman booster and new MC.
Drinky treat to keep me relaxed
This booster fit better so I was able to adjust the light/cruise switch back down some and the pedal was not so high anymore, either. The brake light/cruise switch picture above shows the reman booster rod, you can see the space difference between where the switch was for the TJ booster and where it was going to be for the reman booster. This switch set-up is much easier to work with than the older style that I have seen in some of the write-ups. Anyone know what year it changed?
Here's the reman XJ booster and new MC installed. Aint that purdy?
This parts list posted earlier helped me find what I needed:
You can find these at Advance Auto Parts (drop the .1 when looking the part up). I also sourced the Edelmann adapters from Car Quest, but they were quite a bit more $ there. I didn't use 327819, perhaps that was the adapter I already had in the PV? Also, I'm not sure what 327841 is for, I didn't buy that one. This pic shows the adapters and the custom bent lines:
Conclusions: The braking power is much improved! I'm definitely glad I finally got this done. Make sure you get the 8 mm spacer, you may not need it but it's nice to have if you do. I would recommend not using a TJ booster, the rod is too long and the MC seemed to be at a greater angle.
One more pic of the completed job:
Questions? Comments?
Finally got around to getting the dual diaphragm booster upgrade done this weekend. I had been looking into it for awhile now (there was some good info here on the forum, the madxj write-up, and cagedxj gave me some info, too), but it took awhile to get the courage up to tie into my brakes like that.
Started on Thurs, pulled the old booster and master cylinder (MC):
In this pic, note the adapter in the proportioning valve (PV) on the right, turns out I didn't need to buy one of the adapters because it was already there. More on the adapters later.
I was told that a TJ booster and MC would work for the XJ so I bought one off of e-bay awhile back. I put it in, but the booster rod was too long. I made up for this by putting some washers on the booster mounting bolts to space it out some from the fire wall and I adjusted the brake light/cruise switch out quite a bit, this in turn caused my brake pedal to be quite a bit higher, which I wasn't to thrilled about. I had meant to get the 8 mm spacer from later model XJs and ZJs? but hadn't been able to, I don't think I would have been able to use it anyway, because the booster bolts weren't very long.
Here is a pic of the light/cruise switch, I had pulled it back in it's hole and bent the mounting plate back to make it work: (dis-regard that booster rod, it's not from the TJ booster)
Here is the TJ booster installed, with the custom bent brake lines.
I drove around with that booster on Friday and part of Saturday and was happy with the increased braking power, but the booster had a small vacuum leak (damnit!) and I didn't like having my pedal so high. I had bought a remanufactured '95 booster and new MC in case the TJ booster didn't work, so I figured I would put that in instead. I had trial fit the booster on Thurs before putting in the TJ booster and it seemed to fit pretty good. The rod was also a bit longer than original (shorter than the TJ, though), and I figured I would try to find the spacer. The reman booster had longer mounting bolts, too. Finding the spacer was a PITA and took all of my Saturday morning, but I finally found one and got it off of an 01 XJ. I recommend getting this spacer for this swap.
Saturday afternoon I pulled the TJ booster and put in the reman booster and new MC.
Drinky treat to keep me relaxed
This booster fit better so I was able to adjust the light/cruise switch back down some and the pedal was not so high anymore, either. The brake light/cruise switch picture above shows the reman booster rod, you can see the space difference between where the switch was for the TJ booster and where it was going to be for the reman booster. This switch set-up is much easier to work with than the older style that I have seen in some of the write-ups. Anyone know what year it changed?
Here's the reman XJ booster and new MC installed. Aint that purdy?
This parts list posted earlier helped me find what I needed:
trekfuel80 said:(2) Steel Lines (Part # BL-312) – “BRAKE LINE 3/16 x 12”
(1) Brake Adapter (Part # 327819.1) – “BRASS 3/16FTUBE 5/16TUB”
(1) Brake Adapter (Part # 327818.1) – “BRASS 3/16F TUBE ¼ TU”
(1) Brake Adapter (Part # 327857.1) – “BRASS 3/16IF TO M12-1.0”
(1) Brake Adapter (Part # 327850.1) – “BRASS 3/16IF TO M10-1.0”
(1) Brake Adapter (Part # 327841.1) – “BRASS 7/16-24 TO ¼ TU”
You can find these at Advance Auto Parts (drop the .1 when looking the part up). I also sourced the Edelmann adapters from Car Quest, but they were quite a bit more $ there. I didn't use 327819, perhaps that was the adapter I already had in the PV? Also, I'm not sure what 327841 is for, I didn't buy that one. This pic shows the adapters and the custom bent lines:
Conclusions: The braking power is much improved! I'm definitely glad I finally got this done. Make sure you get the 8 mm spacer, you may not need it but it's nice to have if you do. I would recommend not using a TJ booster, the rod is too long and the MC seemed to be at a greater angle.
One more pic of the completed job:
Questions? Comments?