95 Dual diaphram booster/master cylinder upgrade - JeepForum.com
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post #1 of 69 Old 11-10-2011, 02:33 PM Thread Starter
5.7YJ
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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.


Brake booster and master cylinder from a 1995 Wrangler with 4.0ltr.




Here is the old master cylinder and lines(Needed to be changed on looks alone).




Removed the master cylinder.




I covered up the proportioning valve to prevent debres getting into the system.




Disconected the booster rod from the brake pedal and switch.




Removed the booster leaving the bracket(Looks better already!).




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.




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.




I went ahead and painted the booster with Rusoleum Hamerite paint.




The 95 booster has larger studs(3/8") to mount it to the bracket, I drilled the four holes out to 1/2".




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.




Here is the booster mounted in it's new home.




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.




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.




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.




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!


87 YJ, TPI 5.7, 700R4, NP231, BDS 3.5" lift, 1" front & 5/8" rear boomerang shackles, Rubicon Dana 44 rear axle, 33" Goodyear Duratracs











My brake boster/master cylinder upgrade: http://www.jeepforum.com/forum/f12/9...grade-1287758/
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post #2 of 69 Old 11-10-2011, 02:41 PM
jsawduste
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post #3 of 69 Old 11-10-2011, 02:56 PM
TSEJEEPERS
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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.

93 YJ SOA 2" springs front, XJ springs rear w/main leaf added, High pinon 9 inch rear detroit locker front Dana 44 ARB 4.56 Gears, 36 inch Irok tires too much to list. www.mijc.org
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post #4 of 69 Old 11-10-2011, 02:59 PM Thread Starter
5.7YJ
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Quote:
Originally Posted by TSEJEEPERS View Post
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.

87 YJ, TPI 5.7, 700R4, NP231, BDS 3.5" lift, 1" front & 5/8" rear boomerang shackles, Rubicon Dana 44 rear axle, 33" Goodyear Duratracs











My brake boster/master cylinder upgrade: http://www.jeepforum.com/forum/f12/9...grade-1287758/
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post #5 of 69 Old 11-10-2011, 03:46 PM
jfrabat
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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...

'94 YJ 2.5L with 4" RE lift, Adv. Ad. SYE, Woody Shaft, Superwinch EPi9.0, 62mm TB, FoMoCo e-Fan, SD30 and SD35 w/ARB-4.88, 165A alt., 4 KC aux lights, Aluminum Rad with BRX hoses, 33" BFG KM2 on 15" AR wheels, Sony sound system, Pavement Ends Hardtop, Bosch 19# Injector, Safari Snorkel, 95.5 Brakes
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post #6 of 69 Old 11-10-2011, 04:49 PM
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Outstanding write-up! Photos and part numbers all in one place.
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post #7 of 69 Old 11-10-2011, 05:03 PM
Louie4
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Nice write-up man! You did a good job on the swap.

Lou

I have a jeep...and it is modified...I win.

YJOTM July 2012
YJOTM February 2014

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post #8 of 69 Old 11-10-2011, 05:07 PM
hotelconucc93
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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!

Axles and bolts and springs....Oh My!

My Build Thread --->>> http://www.jeepforum.com/forum/f12/t...ilding-869713/

Not my write up, but now one of my jeeps losing a BA and gaining an AX-> http://www.jeepforum.com/forum/f19/y...ite-up-312203/
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post #9 of 69 Old 11-10-2011, 05:13 PM Thread Starter
5.7YJ
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Thanks for all your comments.

87 YJ, TPI 5.7, 700R4, NP231, BDS 3.5" lift, 1" front & 5/8" rear boomerang shackles, Rubicon Dana 44 rear axle, 33" Goodyear Duratracs











My brake boster/master cylinder upgrade: http://www.jeepforum.com/forum/f12/9...grade-1287758/
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post #10 of 69 Old 11-11-2011, 06:35 AM
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Bookmarked for future refrence. Great writeup!
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post #11 of 69 Old 11-11-2011, 06:51 AM
jay1335
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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?
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post #12 of 69 Old 11-11-2011, 07:20 AM
Que89YJ
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Yes it will be good for you Jay. 1995 on the 4.0L is the year they did it.
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post #13 of 69 Old 11-13-2011, 07:41 AM Thread Starter
5.7YJ
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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!

87 YJ, TPI 5.7, 700R4, NP231, BDS 3.5" lift, 1" front & 5/8" rear boomerang shackles, Rubicon Dana 44 rear axle, 33" Goodyear Duratracs











My brake boster/master cylinder upgrade: http://www.jeepforum.com/forum/f12/9...grade-1287758/
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post #14 of 69 Old 11-13-2011, 12:36 PM
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Nice write up! I did this to my 87 and it was well worth it. Good job.
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post #15 of 69 Old 11-13-2011, 12:44 PM
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What a great upgrade!! Thanks for "photo documenting" it.

Take care,
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