My Hydroboost Conversion - JeepForum.com
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post #1 of 12 Old 05-24-2019, 01:28 PM Thread Starter
orange150
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1982 CJ8 
 
Join Date: Apr 2014
Location: Raleigh
Posts: 902
My Hydroboost Conversion

A few months ago my OE vacuum booster started sounding like it was sucking air through a garden hose. I decided that I wanted to swap to hydroboost brakes for better braking performance.
After some research I discovered that the swap is pretty straight forward, because my Jeep had discs upfront from the factory I wouldn't have to deal with a proportioning valve or anything.
I hopped on RockAuto and ordered a hydroboost unit from a '95 Astrovan, a new MC for an '86 CJ, and ordered the adapter plate from PartsMike.

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IMG_6042.jpg   IMG_6038.jpg   IMG_6037.jpg   IMG_6036.jpg  

'82 CJ-8
258/AX15/D300
OME YJ 2.5"/31s
D30/D44/3.73s/Truetracs
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post #2 of 12 Old 05-24-2019, 01:34 PM Thread Starter
orange150
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From there, I set to removing the original pedal pushrod from the HB unit, as it's too long to connect to the brake pedal, and removing the OE brake components from the vehicle.

I had to remove the Astrovan mounting plate to install and orient the PartsMike plate. The PM plate has two sets of holes, one for a CJ and one for a YJ. Removing the AV plate was a huge pain as it is held on with a large nut that I didn't feel like buying/making a tool for.
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IMG_6142.jpg   IMG_6141.jpg   IMG_6140.jpg   IMG_6169.jpg   IMG_6168.jpg  

IMG_6170.jpg  

'82 CJ-8
258/AX15/D300
OME YJ 2.5"/31s
D30/D44/3.73s/Truetracs
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post #3 of 12 Old 05-24-2019, 01:37 PM Thread Starter
orange150
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Join Date: Apr 2014
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With the PartsMike plate mounted it was time for the biggest PITA of the whole install, making the brake pedal pushrod.

As you can see, there is only about 2.5" of clearance from the front of the HB unit and the mounting stud for the push rod. None of the off the shelf pushrods that I could find even came close to this.
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IMG_6296.jpg   IMG_6276.jpg   IMG_6258.jpg   IMG_6175.jpg  

'82 CJ-8
258/AX15/D300
OME YJ 2.5"/31s
D30/D44/3.73s/Truetracs
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post #4 of 12 Old 05-24-2019, 01:46 PM Thread Starter
orange150
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I couldn't find a source for the ball-end style pushrod that the HB uses, so I cut the one that came on the Astrovan box. I then threaded it 3/8-24 to accept a coupling nut.
Due to the overall length I needed, I had to cut the coupling nut down as well.
I then cut the brake pedal pushrod from the CJ and threaded it to fit the coupling nut.

Once all that was assembled, I realized that I wouldn't have enough room for a jam nut, so I drilled and tapped the coupling nut to accept a set screw.
I also ground a taper on the coupling nut on the HB side so that it would fit inside the cylinder assembly. Again, due to the short length I needed.
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IMG_6305.jpg   IMG_6567.jpg   IMG_6388.jpg   IMG_6569.jpg  

'82 CJ-8
258/AX15/D300
OME YJ 2.5"/31s
D30/D44/3.73s/Truetracs
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post #5 of 12 Old 05-24-2019, 01:48 PM Thread Starter
orange150
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Here it is in the vehicle. This is actually a different setup I tried to use but ended up being too long.

Edit: I don't know why this is flipping some of these images over >
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IMG_6570.jpg  

'82 CJ-8
258/AX15/D300
OME YJ 2.5"/31s
D30/D44/3.73s/Truetracs
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post #6 of 12 Old 05-24-2019, 01:51 PM Thread Starter
orange150
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Next the easy part. You can use a stock CJ master cylinder and the CJ pushrod and it will mount up without issue.

Again, not sure why this is flipping my images over.
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IMG_6598.jpg   IMG_6576.jpg  

'82 CJ-8
258/AX15/D300
OME YJ 2.5"/31s
D30/D44/3.73s/Truetracs
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post #7 of 12 Old 05-24-2019, 01:54 PM Thread Starter
orange150
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For pressure lines, I wanted to use the OE CJ lines on the box and the pump, so then I just had to mock up some lines on the HB side.

I used some hose I had lying around to mock up hose lengths, attached them to the hard lines, marked their orientation and used some hose clamps to clamp them down.
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IMG_6714.jpg   IMG_6715.jpg   IMG_6716.jpg   IMG_6718.jpg  
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'82 CJ-8
258/AX15/D300
OME YJ 2.5"/31s
D30/D44/3.73s/Truetracs
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post #8 of 12 Old 05-24-2019, 02:00 PM Thread Starter
orange150
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Took my mockups to my local line shop, and for $100.00 they made the lines. They aren't the prettiest as the bends are a little tighter than they can usually do, but they don't leak at all.

For the return line, I used some automatic transmission hose and a tee.

Below is a video of it running for the first time. No leaks


'82 CJ-8
258/AX15/D300
OME YJ 2.5"/31s
D30/D44/3.73s/Truetracs
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post #9 of 12 Old 05-24-2019, 02:07 PM Thread Starter
orange150
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1982 CJ8 
 
Join Date: Apr 2014
Location: Raleigh
Posts: 902
After bleeding the brakes and all that fun stuff, this week is my first time driving it around. Took it to work a few days and ran some errands. It DEFINITELY stops better, I feel that the brakes work better in it than they do in my 2017 F-150. They aren't "grabby" either, which I was a little worried about.

I do think there is a better solution to the brake pedal pushrod than what I did, I just need to figure out what it is. I would also like to do the pressure lines a little different since the line shop had a time with those tight bends. If I wasn't such a tight wad I would have rather just bought some of the DIY power steering hose from Earls or one of those companies, but.. $$.

As of right now, I'm definitely glad I made the swap, although a simple vacuum to vacuum swap would have only taken a day or so, and a lot less thinking.

'82 CJ-8
258/AX15/D300
OME YJ 2.5"/31s
D30/D44/3.73s/Truetracs
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post #10 of 12 Old 05-25-2019, 06:49 PM
scooby533
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Great write up, thanks!
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post #11 of 12 Old 05-25-2019, 07:15 PM
trailhead2004
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Quote:
Originally Posted by orange150 View Post
Again, not sure why this is flipping my images over.
I know iPhones do this a lot. For whatever reason up isnít necessarily up to the phone. I usually end up having to download the picture to my PC and rotate them on the image viewer before posting.
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post #12 of 12 Old 05-25-2019, 11:40 PM
schardein
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I did a similar swap. Mine is a YJ tub. I used a weld together bracket I got off ebay. Used the Astro van master cylinder. The stock CJ lines hook up to it like factory (although I used stainless steel lines). The longer adapter bracket means no mods for the brake rod.

I used to run a factory CJ power brake setup, then switched to a YJ dual diaphragm vacuum booster. There is no comparison with the Hydroboost.
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1983 CJ7, 5.3, NV3550, D300 4:1, Fr D44 Detroit, Rr D44 OX, 4.56, 35" SSTs on beadlocks
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