Brake Booster Upgrade CJ7

[JAG811]

A fair way back now I ordered an after market booster and master cylinder for the CJ.
Now, it's not as simple as just bolting it in so I thought I'd put together a thread so that others can do the same if they to have no power assisted brakes.

Things to consider.

• Size of the booster.
• Clearance from the hood.
• You'll also need some new lines as the booster, and or the extension brackets will push the master cylinder forward.
• It's not a direct bolt on job.

Pic 1 - So I ordered an 8" booster and master cylinder straight off ebay.
After taking some measurements and messing around a little I was positive it wouldn't foul on anything.

 

[JAG811]

1. You'll need to undo the pedal linkage from inside the cab.
2. Then undo the two master cylinder bolts to loosen it.
3. You'll need to then look at tracing the two lines down to the Brake Proportioning Valve and undo them from there.
These will almost always give you difficulty and I had to use Vice Grips after purposely buying a high quality pipe spanner, that still looked as though it would have spun the edges off (strip) the nut.
4. Then you can remove the master cylinder - Brake lines still attached.

It's probably important to remind everyone I'm Down Under and so yes, it's all on the wrong side

 

[JAG811]

Once removed you'll need to take the Brake Booster Assembly and start to measure out on the firewall where you'll need to drill some holes.

Pic 1 - I marked the firewall horizontally across the two original mounting holes to assist with keeping the new assembly horizontal.

Pic 2 - I also marked the booster brackets to allow me to hold the whole assembly against the firewall to assist with locating, centre punching and drilling of the first hole.

Pic 3 - With just the one hole drilled, you can mount the assemble, so as to mark the other three holes that you'll need to drill out.

Pic 4 - Understanding the body on my CJ needs some attention. And so the (Aussie) drivers side sits lower then it should by about 3/8 of an inch.
So I lifted the body slightly to correct it to where it should sit, after I've looked at fixing that body mount. The trusty old level was used to make sure I was happy with where the master cylinder would finish up.

 

[JAG811]

Once all four holes were drilled out and the assembly test fitted, it was obvious that the Booster Assembly Mounting Brackets were going to cover the square hole the accelerator cable moves through.
So I marked enough room to get it through and with a 4" grinder cut in a nice half circle, and then had to respray the bracket.

 

[alpha6]

And?? does it work? Come on Jon...don't leave us hanging. Also...I am starting to think you actually have the wife doing all your work...no way your hands can stay that clean working on the jeep.

 

[thiswontbetooexpensive]

IDK about Jon, but I will only let the kids help me with my jeep. As far as my Wife is concerned, this is the most complicated thing a man can undertake and it requires hours of intense concentration assisted by copious amounts of cold beer!
Look great BTW. I'm going to have to print your build thread and keep it close when I get back at at...

 

[JAG811]

I'll try to have all of the pedal linkages sorted today.
And hopefully the lines will be next weekend.



I was taught by one of my supervising mechanics once, "A professional stays clean and keeps the vehicle clean". But he hated the stigma of mechanics are all covered in grease 24/7.

 

[alpha6]

So you are saying looking like this makes me a poor mechanic? Good luck getting those lines hooked up today.

 

[JAG811]

Pulled everything off to get to the pedal linkages and once I started putting it together I realised I was not going to be happy with the play in the "two washers and a split pin" they send you.

So I tapped the two pins so as to get a pair of nylock bolts on.
Given they're in the extension brackets, by some chance if they were to loosen up they couldn't fall off anyway- You'll notice it's pretty tight in there.

Mounting the assembly, and pedal linkages - Check.

Still have to look at the lines, and additionally, I'm fitting an adjustable proportioning valve, which means flaring lines to fit the different brake line fittings.

More pictures to come as I go.