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Jeep Wrangler YJ
YJ Build Threads & Member's Rides
My '94 Hunter Green “No Compromises" Build
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<blockquote data-quote="machoheadgames" data-source="post: 428145" data-attributes="member: 18789"><p><strong>Dave's Customs Unlimited Brake Booster & Master Cylinder</strong></p><p></p><p>My next 2019 project was to replace the brake booster and master cylinder with an "upgraded version". if you recall from Post #8, I was running the booster and master cylinder from a 95 4.0L YJ. With the bigger WJ brakes (and Vanco big brake kit when I had it), braking in the rain was sort of dangerous. I now had so much brake power that when streets were slick, the brake pedal was more of an on-off switch. It was very difficult to use the brakes without locking them up and sliding. I had a very few close calls where I nearly plowed straight into people at 30mph. As a result, I wanted to dial the performance back a bit, while still being good enough to lock up in all dry conditions. As such, I decided to try the Dave's Customs kit. When ordering this kit, you need to choose a master cylinder bore size. I opted for 1" as that is the proper size that flows the correct amount of fluid and produces the right amount of pedal effort for both WJ calipers and the Vanco brakes.</p><p></p><p>One of my YJ buddies came from out of town and we knocked out the install in a few hours and bled the brakes. He brought his awesome Eastwood brake line flare tool and flared me some custom lines in minutes. I definitely need to get that tool.</p><p></p><p>We took the Jeep out for a drive and honestly, the results were depressing. I was no longer able to lock up the tires. My friend thought it was decent but he is considerably larger than me and definitely has more power in his leg than I do. The most I could get was some light chirping. When braking, you have a nice amount of vacuum at first, and then about halfway into the pedal it feels like you run out of vacuum and have a bad booster. The pedal feels like a brick wall and is very difficult to get any decent braking power out of. I also noticed that after letting off the brake pedal, it feels like vacuum is still applied for a second or so. The rod is adjusted properly so I'm not really sure what else should have been done. I reached out to Dave to make sure I had received the proper master cylinder, and I had. I checked the forums and Facebook and found some other negative feedback that matched mine. Much worse braking power than stock, hard pedal, etc.</p><p></p><p>I also had to grind a considerable amount out of the outer shell of the booster to avoid it hitting my clutch master cylinder. Even so, it still interferes. This is definitely not a perfect swap for a YJ...in hindsight, I should have just gone back to the stock 87-94 single diaphragm booster and master. Not long after the Dave swap, I went ahead and purchased those parts and considered the Dave setup a loss.</p><p></p><p>Here is the Dave's setup installed</p><p></p><p>[ATTACH]116951[/ATTACH]</p><p></p><p>Here is a picture of the interference between the clutch MC and the booster. I'm pretty certain I'd have a busy day if I needed to change the clutch MC.</p><p></p><p>[ATTACH]116952[/ATTACH]</p><p></p><p>Here are the reworked brake lines using nickle copper lines and the proper tube nuts to fit all the ports.</p><p></p><p>[ATTACH]116953[/ATTACH]</p><p></p><p>Another really disappointing aspect of this brake booster kit is that they offer no options to cover the giant firewall hole. The boot doesn't reach and the factory booster boot doesn't work either. Seriously, seeing how this swap turned out makes me wonder if they've actually ever installed it on a YJ, lol. Granted that's a joke because they advertise it on a YJ in the pictures, but still....</p><p></p><p>[ATTACH]116954[/ATTACH]</p></blockquote><p></p>
[QUOTE="machoheadgames, post: 428145, member: 18789"] [B]Dave's Customs Unlimited Brake Booster & Master Cylinder[/B] My next 2019 project was to replace the brake booster and master cylinder with an "upgraded version". if you recall from Post #8, I was running the booster and master cylinder from a 95 4.0L YJ. With the bigger WJ brakes (and Vanco big brake kit when I had it), braking in the rain was sort of dangerous. I now had so much brake power that when streets were slick, the brake pedal was more of an on-off switch. It was very difficult to use the brakes without locking them up and sliding. I had a very few close calls where I nearly plowed straight into people at 30mph. As a result, I wanted to dial the performance back a bit, while still being good enough to lock up in all dry conditions. As such, I decided to try the Dave's Customs kit. When ordering this kit, you need to choose a master cylinder bore size. I opted for 1" as that is the proper size that flows the correct amount of fluid and produces the right amount of pedal effort for both WJ calipers and the Vanco brakes. One of my YJ buddies came from out of town and we knocked out the install in a few hours and bled the brakes. He brought his awesome Eastwood brake line flare tool and flared me some custom lines in minutes. I definitely need to get that tool. We took the Jeep out for a drive and honestly, the results were depressing. I was no longer able to lock up the tires. My friend thought it was decent but he is considerably larger than me and definitely has more power in his leg than I do. The most I could get was some light chirping. When braking, you have a nice amount of vacuum at first, and then about halfway into the pedal it feels like you run out of vacuum and have a bad booster. The pedal feels like a brick wall and is very difficult to get any decent braking power out of. I also noticed that after letting off the brake pedal, it feels like vacuum is still applied for a second or so. The rod is adjusted properly so I'm not really sure what else should have been done. I reached out to Dave to make sure I had received the proper master cylinder, and I had. I checked the forums and Facebook and found some other negative feedback that matched mine. Much worse braking power than stock, hard pedal, etc. I also had to grind a considerable amount out of the outer shell of the booster to avoid it hitting my clutch master cylinder. Even so, it still interferes. This is definitely not a perfect swap for a YJ...in hindsight, I should have just gone back to the stock 87-94 single diaphragm booster and master. Not long after the Dave swap, I went ahead and purchased those parts and considered the Dave setup a loss. Here is the Dave's setup installed [ATTACH alt="IMG_1839.jpeg"]116951[/ATTACH] Here is a picture of the interference between the clutch MC and the booster. I'm pretty certain I'd have a busy day if I needed to change the clutch MC. [ATTACH alt="IMG_1840.jpeg"]116952[/ATTACH] Here are the reworked brake lines using nickle copper lines and the proper tube nuts to fit all the ports. [ATTACH alt="IMG_1841.jpeg"]116953[/ATTACH] Another really disappointing aspect of this brake booster kit is that they offer no options to cover the giant firewall hole. The boot doesn't reach and the factory booster boot doesn't work either. Seriously, seeing how this swap turned out makes me wonder if they've actually ever installed it on a YJ, lol. Granted that's a joke because they advertise it on a YJ in the pictures, but still.... [ATTACH]116954[/ATTACH] [/QUOTE]
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Jeep Wrangler YJ
YJ Build Threads & Member's Rides
My '94 Hunter Green “No Compromises" Build
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