dkmcgowan Posted December 9, 2015 Share Posted December 9, 2015 I upgraded the 89 Comanche with a 96 Cherokee XJ booster and master cylinder. The brakes work fine, but the pedal is way too low. It's at the same level as the gas pedal, when it should be at the same level as the clutch pedal. I kept reading on the forum that if I used an 96 XJ booster, it should work fine and the pedal height would be good as long as you used a spacer. I believe I have the then spacer included, but that still makes no sense, because a spacer would make the pedal go even lower??? Here are some pictures. I really want my pedal height to be back, or closer, to where it was before. I also want to avoid the cutting and welding of the brake rod, seems dangerous. Any thoughts? Link to comment Share on other sites More sharing options...
cruiser54 Posted December 9, 2015 Share Posted December 9, 2015 The spacer is aluminum and should be behind the booster. But that would make the pedal lower. Is the booster seated on the firewall properly? Link to comment Share on other sites More sharing options...
dkmcgowan Posted December 9, 2015 Author Share Posted December 9, 2015 I will try to unbolt and wiggle it around some, but the top is for sure flush against the firewall and the bolts are all tight. There isn't that much room in those holes, so if all 4 bolts go in, didn't think it could really be lined up wrong.Hope I don't have to pull those lines and bleed this thing again :( Link to comment Share on other sites More sharing options...
dkmcgowan Posted December 9, 2015 Author Share Posted December 9, 2015 I just went and looked and it seems flush against the firewall and all the bolts are sticking into cab about the same amount. Are there some other boosters that just have shorter rods? I also changed out the pedal assembly, so it's a newer style clutch/brake assembly, but the clutch sits where it should. Link to comment Share on other sites More sharing options...
dkmcgowan Posted December 9, 2015 Author Share Posted December 9, 2015 I got the booster/cylinder from a friend, said it was 96 XJ, maybe it was a ZJ? I read though those even will work as long as you remove the spacer, which I don't think is there. Link to comment Share on other sites More sharing options...
HOrnbrod Posted December 9, 2015 Share Posted December 9, 2015 I just went and looked and it seems flush against the firewall and all the bolts are sticking into cab about the same amount. Are there some other boosters that just have shorter rods? I also changed out the pedal assembly, so it's a newer style clutch/brake assembly, but the clutch sits where it should. What pedal assembly did you use? The 91 and up XJ/MJ pedal assembly? If so, the booster rod eye slides on to a pin (#13) on the brake pedal circled in red in the drawing below. In looking at your pic above, it does not. Link to comment Share on other sites More sharing options...
dkmcgowan Posted December 9, 2015 Author Share Posted December 9, 2015 I went and checked again, the spacer was there. I pulled the master cylinder back and to the side, pulled the booster out, and removed the spacer, and installed again. This brought the pedal back up maybe half way to the clutch. So it's better, at least it's not at the same height as the gas pedal. I also checked, the pedal assembly I picked up to convert from auto to manual must have been the older renix style. we had to modify it to work with the old style brake switch and it doesn't look like that picture. We shaved down one side of the circle on the brake rod from booster to make the switch fit. I didn't drill it out and put the bushing in there, just put it on without the bushing, so not sure if that's really bad or not. I also called my friend, he thinks it could have been from a 97, but was pretty sure it was an XJ, I think it was a ZJ. So I'm happier now, but wish it was all the way up. I had read that even if it was a ZJ, if you remove the spacer, it should be the right height, who knows. Link to comment Share on other sites More sharing options...
dkmcgowan Posted December 17, 2015 Author Share Posted December 17, 2015 So I decided I want the pedal all the way back up. If I just purchase a 95 XJ reman brake booster, will the master cylinder I have fit right onto the new booster if this unit is from a YJ/ZJ? Link to comment Share on other sites More sharing options...
dkmcgowan Posted December 17, 2015 Author Share Posted December 17, 2015 I did some research, looks like the 1996 Grand Cherokee booster is what I have in there, and the rod is a decent amount shorter on that one. I'm going to get the 1996 Cherokee brake booster, should solve my height problem. Also, the master cylinders are exactly the same on both, so I don't have to bleed again, change lines, etc... I will just push the master cylinder out of the way and replace the booster. Glad I figured it all out, thanks! Link to comment Share on other sites More sharing options...
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