Kung Fu Brakes One Ton Brake upgrade

[Alaska ZJ]

Alright I have to first give credit where credit is due. BigDude from the Pirate Bullitin BOard tried this first (at least to my knowledge) and directed me on what to look for and do.

His was a YJ and he just had to do the MC (Master Cylinder). Well our ZJ's have a double diaphram booster and the E350 MC will not work with it. So I snatched a single diaphram booster off of a 88 XJ. Booster bolted right up inplace of the the old booster.

The pedal is going to be very stiff. Personally I like it like this. I seem to have more control over my brakes. Now my wife who is on the small side absolutly hates the brakes in the Chuggy. She thinks it takes WAY to much pressure to get the brakes to catch hard. BUT they will catch hard. I have locked all 4, 36 inch TSL's at about 40 mph. I can stop going down Launchpad in Moab without so much as a worry.

Anyway here is the write-up page. Feel free to fire any questions.

http://www.akextreme4x4.com/tech/bra...r_cylinder.htm

and because threads without pictures suck. Here is the E350 master mated up to the 88xj Booster installed on my 93 ZJ.

[Trancezj]

So you do away with this and put a new one in?

[Trancezj]

I ask because I don't see anywhere on the other part to put fluid in

[Alaska ZJ]

that is the Stock ZJ mastercylinder. You no longer need it or anything attached to it. I just wanted to show what it looked like and why the E350 would not bolt in it's place.

[Nordic1]

Brent, did you bolt up the master cylinder to the stock lines (with the ABS crap) or did you route new lines?

[Nordic1]

edit: never mind i read your writeup on the other page... you did bypass the ABS. Do the brakes ever lock up funny without the proportioning valve?

[Alaska ZJ]

No, the brakes are very predictable. The rear actually engage the same time as the fronts without the proportioning valve.

This is fine for me. It is different than the stock form though. In the stock form the fronts will grap slightly prior to the rears engaging.

Also with the single diaphram booster it takes some leg power to get everything stopping. My wife doesn't like to drive the chuggy for this reason. I just push harder....but she thinks the brake pedal is too hard and that it takes to much input to get good braking out of the system.

A double diaphram XJ booster will work inplace of the single diaphram XJ booster I used. Direct bolt in swap.

[deadman]

Has anyone tried the corvette MC?

I've searched on pirate and my brain hurts now... I got all kinds of MC out of the search. Dodge 3500, Pontiac Firebird, Corvette, E350, and a Mercury one.

From what I read the E350 MC is only for front discs and rear drums.
Since one reservoir is smaller than the other.

I got discs at all corners, two calipers for each disc. So I got a lot of fluid to move. Has anyone done the Kung Fu brakes with all disks, and what MC did you use?

thanks
Sascha

[deadman]

nobody?

[MaineZJ]

you got 8 calipers? what you turning - 62s or something?

[deadman]

No, just 42s for now.
But my new axles come stock with 2 calipers...

[Nordic1]

I didn't catch it the first time but looking at this again...



portals? bastid

[deadman]

Still don't know what to do about the brakes tho. I guess I'll just have to try the E350 Master, and see if it works. But try finding one in Germany!

[ATL ZJ]

Still don't know what to do about the brakes tho. I guess I'll just have to try the E350 Master, and see if it works. But try finding one in Germany!

I can pull one and mail it to you. How much is it worth to ya?

[Kraqa]

I didn't catch it the first time but looking at this again...



portals? bastid

hmm i think there volvo's not portals.

[deadman]

I can pull one and mail it to you. How much is it worth to ya?

I don't know about a used one... but how about the next time someone gets something for themself at NAPA, they buy me the remanufactured one that Alaska bought?




In his write-up he says it costs $25... + $20 for your troubles + shipping.


@Kraqa: That is a 406 Unimog axle... not an actual pic of my one, but I got the same axle.

[scubatch2]

if I have disc at all 4 corners will this work ok,or should I get the double diaphram booster?

[nate]

Looks like a portal axle to me. Volvos use portal axles.

hmm i think there volvo's not portals.

[JeepinJoe]

Ok so why not use a WJ booster and m/c setup instead? Doe's that E350 MC make that big of differance?

[JPZJ]

Ok so why not use a WJ booster and m/c setup instead? Doe's that E350 MC make that big of differance?

I'd like to know also...can anyone tell me and Joe why not use the WJ stuff as opposed to the XJ /E350 setup

I've got disc/disc set up also ...Thanks

[JPZJ]

Can anyone commnet on the WJ booster/MC as opposed to using the Ford stuff ?

[ELLLLLIOTTTTT]

BTT... I got an 88 XJ booster but I'm trying to decide which master cylinder to use. Corvette MC?

[Jim311]

Can anyone commnet on the WJ booster/MC as opposed to using the Ford stuff ?

A friend of mine runs a WJ booster in his XJ. You might search over at NAXJA for some more info about it. He says his 4wd XJ on 33s stops better than his 2WD daily driver Cherokee.

[zj95]

will a booster out of a 92 xj work?

[Alaska ZJ]

will a booster out of a 92 xj work?

Yes