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-   -   95 Dual diaphram booster/master cylinder upgrade (http://www.jeepforum.com/forum/f12/95-dual-diaphram-booster-master-cylinder-upgrade-1287758/)

5.7YJ 11-10-2011 02:33 PM

95 Dual diaphram booster/master cylinder upgrade
 
After a few to many close calls trying to stop the Jeep, I ended up doing the 95 dual diaphram booster upgrade. After doing some research and reading as many post on here that have done this, I went out and bought the parts and completed the swap. Here are some pictures and descriptions of how everything went for me.

http://i892.photobucket.com/albums/a...1Boosterpt.jpg http://i892.photobucket.com/albums/a...ercylinder.jpg
Brake booster and master cylinder from a 1995 Wrangler with 4.0ltr.



http://i892.photobucket.com/albums/a...Stocksetup.jpg http://i892.photobucket.com/albums/a...Stocklines.jpg
Here is the old master cylinder and lines(Needed to be changed on looks alone).



http://i892.photobucket.com/albums/a...m-cremoved.jpg
Removed the master cylinder.



http://i892.photobucket.com/albums/a...p-vcovered.jpg
I covered up the proportioning valve to prevent debres getting into the system.



http://i892.photobucket.com/albums/a...isconected.jpg
Disconected the booster rod from the brake pedal and switch.



http://i892.photobucket.com/albums/a...terremoved.jpg
Removed the booster leaving the bracket(Looks better already!).



http://i892.photobucket.com/albums/a...difference.jpg
Here is one difference between the 87 and 95 rod, the 87 rod hole is 5/8" and the 95 is 9/16" I believe. The other is the 95 rod is 1/4" shorter than the 87. I didn't worry about the 1/4" difference and can't really tell now that it's in.



http://i892.photobucket.com/albums/a...illedoutto.jpg
Here is the rod after I drilled it out to 5/8", one of my friends had a bit or it would have cost me another $20.



http://i892.photobucket.com/albums/a...osterpaint.jpg
I went ahead and painted the booster with Rusoleum Hamerite paint.



http://i892.photobucket.com/albums/a...Drillmount.jpg
The 95 booster has larger studs(3/8") to mount it to the bracket, I drilled the four holes out to 1/2".



http://i892.photobucket.com/albums/a...ountground.jpg
One issue I had was the brake light switch would not fit due to the casting at the end of the rod(later models use a different switch). I used an angle grinder and removed material until the mounting pin would fit with the switch on. I also had to bend the small tabs on the switch towards the rod end to get it to work properly.



http://i892.photobucket.com/albums/a...termounted.jpg
Here is the booster mounted in it's new home.



http://i892.photobucket.com/albums/a...rsandlines.jpg http://i892.photobucket.com/albums/a...eradapters.jpg
Due to the master cylinder having bubble type fittings, I purchased adapters for the master cylinder. The fittings you will need are Edelmann #265000 and #271300. They both adapt to standard 3/16 brake line fittings. The lines I used where Carquest #NC320, they are nickle/copper and bend really nice.



http://i892.photobucket.com/albums/a...edinglines.jpg
I went and bought an extra line and cut it in half to make bleeded lines. I really don't like using those plastic plugs that come with the master cylinders.



http://i892.photobucket.com/albums/a...veadapters.jpg
Here are the adapter lines for the proportioning valve. I was going to reuse the original fittingsand double flare the lines myself but just could not get them to flare the way I wanted.



http://i892.photobucket.com/albums/a...scompleted.jpg http://i892.photobucket.com/albums/a...3Completed.jpg
Here is the finished product, looks a whole lot better than it did with the old setup.

I bled all of the lines to get any air out and to flush out all of the old fluid.

I took it out for a test drive and I have to say it brakes a lot better than before(and I thought it wasn't that bad before). I don't think I will have to stand on the brake pedal any more when some idiot pulls out in front of me and decides to stop. The entire swap cost less than $250.00 and it was worth every penny!

jsawduste 11-10-2011 02:41 PM

:thumbsup:

TSEJEEPERS 11-10-2011 02:56 PM

Looks good.
Did you have any problems finding the 95 booster and master cylinder?
When I did my brake upgrade I had a heck of a time finding the booster.
No one local could get it, I finally found it online.

5.7YJ 11-10-2011 02:59 PM

Quote:

Originally Posted by TSEJEEPERS (Post 12480897)
Looks good.
Did you have any problems finding the 95 booster and master cylinder?
When I did my brake upgrade I had a heck of a time finding the booster.
No one local could get it, I finally found it online.

Thanks. No problem at all, went down to the Carquest I deal with a lot and had it in a couple of days.

jfrabat 11-10-2011 03:46 PM

I did this upgrade as well a while back... It did improve my braking, but me being me, I could not let good enough alone, so I went to hydroboost. HB does work better, but now when I stall the engine, I loose brake booster, which makes it rather interesting when you stall on a steep slope...

Come On Comet 11-10-2011 04:49 PM

Outstanding write-up! Photos and part numbers all in one place.

Louie4 11-10-2011 05:03 PM

Nice write-up man! You did a good job on the swap.

hotelconucc93 11-10-2011 05:07 PM

Nice man. I put the Ford E-350 master cylinder in mine. Was much cheater, but I really like your route also.

Need that stopping power!

Good man!

5.7YJ 11-10-2011 05:13 PM

Thanks for all your comments.

Que89YJ 11-11-2011 06:35 AM

Bookmarked for future refrence. Great writeup!

jay1335 11-11-2011 06:51 AM

What year jeeps will this benefit? I have a 94 yj with the 4.0. I guess im wondering if anyone knows what year they changed everything to the better stuff?

Que89YJ 11-11-2011 07:20 AM

Yes it will be good for you Jay. 1995 on the 4.0L is the year they did it.

5.7YJ 11-13-2011 07:41 AM

I had a minor issue come up with the swap, one of the adapter fittings on the master cylinder was leaking. I took the fitting out and looked it over real good and it looks like it was machined wrong. I bought another fitting and after giving it a once over, installed it. The new fitting worked and there are no more leaks!

Virjeep 11-13-2011 12:36 PM

Nice write up! I did this to my 87 and it was well worth it. Good job.

1SASjeepster 11-13-2011 12:44 PM

What a great upgrade!! Thanks for "photo documenting" it.

Take care,


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