So after spending the evening reading threads on Pirate - I am no closer to a conclusion than I was before. I did learn a lot...(I will quailfy this with I am no brake master or I would not be here at this point with this problem).
What I had:
4 Wheel disk -Supposedly the rears are the same as Explorer from what read on a post from a relative expert
From what I read - the PV in Jeeps is the same, regardless of disk/disk or disk/drum
Mr. N and other have some useful info. If I read it right:
Ford OEM MC bore is 1 1/16
2005 TJ is 1 inch or 1 1/16
Ram 2500 is 1 1/4 or 1 5/16
Ford MC bore for disk/drum is 1 1/4
I read in Mr. N's thread about how to measure the piston bore. I can't make sense of the MC I took out of my TJ (I bought it with disk/disk and have no idea if it was a mod or factory and same for MC). When I put the calipers up to the inside of the bore I get about 1.36" and when I do it just to the edges of the inner plastic molding on the face of the piston I get 1.23." This leads me to believe it is 1 1/4". Can that be? This is all larger than I understand it to(should) be.
This relates to many posts about the 2500 MC being a problem more than a solution. Granted that seems to be more in the case of using stock Jeep calipers and not one ton's. There is the "E350" swap out there. I havent had time to read up on that tonight.
After reading a number of the posts about retaining the 1" bore Jeep MC for more clamping pressure as opposed to the more fluid pushed by the 2500 MC, I am inclined to put the Jeep MC back in. Now I am confounded in that I don't see how mine was one inch or 1 1/16. According to the Mr N. thread the TJ only had a 1" or 1 1/16" bore, but there is no indicatoin in that thread of what TJ got what. I could assume I should have a 1 1/16 due to the disk/disk? If so, is it the same as the Ford 1 1/16?
All that said, I feel no slack in my pedal which leads me to believe the push rod is where it needs to be, at least in gross terms. So why is one caliper not engaging? Do I need to dial it out more to push more fluid?
One exception that was always noted on Pirate was that the MC change was not need unless you went one ton calipers...
So, is it all about hydro boost or is there a more fundamental problem? Bad caliper, push rod...
Well that is where I leave the day... I can't come to an acceptable stop and...
when I went out into the garage to get my calipers and original MC, I found a nail in my rear passener side 40 from my drive around the block