XJ axle swap/build

[XJensen]

Originally Posted by DocTremp

Did some digging and WJ booster isn’t compatible with the Durango/Dakota MCs. Need a 97-01 booster now.


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I think I tossed it but I might have one

[89Mock]

Originally Posted by DocTremp

Did some digging and WJ booster isn’t compatible with the Durango/Dakota MCs. Need a 97-01 booster now.


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I wish I knew what you were doing. I learned the hard way too. It needs to be 3 1/2” spacing for the studs to line up with the master cylinder. Have you checked a Dodge Ram 2500 from the 98-2000 year? Maybe a local parts store has one you can measure.

[DocTremp]

So I ended up using the same MC as Nate, and it fit fine but the push rod in the booster (97-01) was too long and my pedal was bottoming out in the MC about 3 inches from the firewall. I now have a 96 booster which is supposed to be the correct one that works with 86-94 (I think) XJs. But on top of that I have not been able to get a good hard pedal. Bled it 3-4x in the correct pattern. Going to put this new booster in and bleed it again. Hopefully i can get it bled right this time.


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[Goose_XJ88]

Being a 90 with a 95/96 booster, you will need to grind down a section of the rod for your brake switch to work. Or you can retrofit a later model switch and figure a way to have it hit the pedal. Otherwise your brake lights won't work.

[89Mock]

Sooo V8 durango master cylinder and brake booster off a 96 XJ with the pedal hella modified so it connects to the stock pedal?

[DocTremp]

Originally Posted by Goose_XJ88

Being a 90 with a 95/96 booster, you will need to grind down a section of the rod for your brake switch to work. Or you can retrofit a later model switch and figure a way to have it hit the pedal. Otherwise your brake lights won't work.

Yes, that’s been done. I think it’s the flasher or a ground. Found I have a lot of air in the system regardless of bleeding it a lot


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[DocTremp]

Originally Posted by 89Mock

Sooo V8 durango master cylinder and brake booster off a 96 XJ with the pedal hella modified so it connects to the stock pedal?

I would say mildly modified.


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[89Mock]

Gotcha. I have the WJ booster and (probably) the stock 89 master and the brakes are horrible on mine with a Dana 60 front. They were great with stock axles though. The Durango master wouldn’t fit the booster so I’m now fishing for something different.

[Phil]

I have straight up manual brakes on the buggy, with Ford dual piston Dana 60 calipers up front and the typical 3/4 ton Chevy front calipers in the rear, and it’s pretty nice. Buggy though so I don’t really get past second gear in high range.

[DocTremp]

Originally Posted by 89Mock

Gotcha. I have the WJ booster and (probably) the stock 89 master and the brakes are horrible on mine with a Dana 60 front. They were great with stock axles though. The Durango master wouldn’t fit the booster so I’m now fishing for something different.

Yeah. I had a similar set up with stock axles and it was awesome. Now I have a similar set up to Phil, and it giving me fits getting it bled. You might want to look into 96 booster. It fit well for me with the Durango mc.


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[DocTremp]

Originally Posted by Phil

I have straight up manual brakes on the buggy, with Ford dual piston Dana 60 calipers up front and the typical 3/4 ton Chevy front calipers in the rear, and it’s pretty nice. Buggy though so I don’t really get past second gear in high range.

I have a similar set up but I have the el dorado calipers with the ebrake arm. What mc/booster are you running?


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[89Mock]

Originally Posted by DocTremp

Yeah. I had a similar set up with stock axles and it was awesome. Now I have a similar set up to Phil, and it giving me fits getting it bled. You might want to look into 96 booster. It fit well for me with the Durango mc.


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I found a 95 booster and discovered the Ram 1500 has the same master. So now I need to apparently adjust the booster rod length and install everything.

[Phil]

Originally Posted by DocTremp

I have a similar set up but I have the el dorado calipers with the ebrake arm. What mc/booster are you running?


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I have no brake booster. I have a CNC dual master cylinder. I don’t have the size listed electronically, I think I must have ordered from Kartek over the phone, and will dig through my stack of receipts to see if it is there.

[DocTremp]

Originally Posted by 89Mock

I found a 95 booster and discovered the Ram 1500 has the same master. So now I need to apparently adjust the booster rod length and install everything.

I got the 96 and I didn’t have to adjust the booster push rod.


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[DocTremp]

Originally Posted by Phil

I have no brake booster. I have a CNC dual master cylinder. I don’t have the size listed electronically, I think I must have ordered from Kartek over the phone, and will dig through my stack of receipts to see if it is there.

Oh I got you. Thanks! That would be cool to look into.


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