(another) 92 XJ ABS removal / 95-96 MC/booster upgrade

92 XJ, gonna remove my ABS and swap in a 95-96 booster/MC. Note: 91 and older ABS system is different, I think there’s be pressure you’re gonna want to relieve. Pulled the air cleaner to make room, pulled the MC and ABS system as one unit. There’s a few plugs on the ABS I just taped up.

Bought both parts separatley so I test fit them to make sure the rod in the booster wasn't too short or long. Can be adjusted if need be. MC part # Dorman M390303, Booster # 54-73152

Clip needs to be pulled off brake pedal to pull out booster.

The pin hole for the brake pedal rod was the same size but the rod itself was a bit longer ~ 3/8-1/2". I used a piece of hard foam to create that space. In hindsight shoulda used plastic cause the foam compressed a bit. Still worked out.

Got a ZJ proportioning valve (I have an 8.8 with discs) whos fitting lined up good to the MC but it was out of a ZJ with ABS so one of the front line fittings was plugged. Got a T fitting which helped that. I guess I coulda searched more in the JY for a ZJ without ABS or even found the plug ( T-fitting )

Awsome flare tool well worth the money.

2 out of 3 flares without forgeting to put the nut on ain't bad right?

Bench bled the MC, hand mangled the lines to line everything up (yes it coulda been pretier) then just did one round of bleeding.

Reference I used to set up lines


Took it for a test drive. Was a little spongey at first but after some more braking I came close to locking up my 35s. Real happy with the new braking and I know I need to bleed it a bit more. When I parked I noticed the rear line at the prop valve was weeping a bit so need to fix that. That sums it up, if I forgot anything please chime in.

Can you clarify what the foam was spacing? Was it shimming the booster out from the firewall to account for the longer rod, or something else?

I have the same flaring tool. By far, the best one I've used. I think paid $36 for it

paulhead said:

2 out of 3 flares without forgeting to put the nut on ain't bad right?

Click to expand...

Glad I'm not the only one. lol

Rob Mayercik said:

Can you clarify what the foam was spacing? Was it shimming the booster out from the firewall to account for the longer rod, or something else?

Click to expand...

Exactly also space the booster away from the firewall which the foam is not doing well :dunce:

This picture shows a booster with the spacer

To prevent you from disassembling everything to fix the spacing, could you leave the foam in there and slip some slotted spacers in around the bolts?

That's a good idea, was wondering that, thnx

Fixed the leak, 2 rounds of bleeding and brakes are tight, stop great. Cleaned up the mangled lines, don't know why I do rush jobs and not do it right the first time.
Before


After