1991Jeep_Man

Evening everyone!

I know part of this question would probably be in the other Tech sub-forum, however I also have a question related to OEM operation and repair.

First off, the door. My driver's door does not like to hold open like it should. It's done this for a while now; hasn't always done that though. I have noticed that the little bar above the rubber grommet thing that the speak wire goes through likes to shift up and down when opening and closing the door. It appears that the little pin in the body end is loose. Thoughts? Repair?

Second, disc brakes. Rear disc brakes. Please all conversion-ies weigh in here. My Jeep is a '91 XJ with what I am assuming is the single diaphragm brake booster with the metal master cylinder with metal lid. My drums are still kind of acting up, and I hate them. They suck and fail at life. I have the ZJ backing plates needed for the conversion that I will be stripping and painting with a flat black high heat paint. What else do I ABSOLUTELY need for this swap?

I know rear calipers from some year ZJ, preferably new axle seals (D35) since I'll be there anyway, new e-brake cables, rotors, pads, e-brake shoe/hardware... Do I need the new prop valve yet or can it wait? Also, do I need to swap out the master cylinder or reservoir? Trust me, I will do whatever is necessary and if the Prop valve makes a notable safety difference then I will get. Just need the input.

Also, when you remove the rear axles, how does that jank work? I know the D35 is c-clip and there is mention of a pinion shaft bolt (8mm I think). You are supposed to remove this (one?) bolt and push the axles in, magically releasing the clips and then you can pull the axle. Fill me in please.

Thank you everyone!

1991Jeep_Man

Also, is it true a 95-96 Xj brake booster/master cylinder assembly will directly bolt into an older (my '91) Cherokee?

Turbo X_J

Search will provide you with at least a gazillion answers:

Google: site:cherokeeforum.com rear disc conversion

Google: site:cherokeeforum.com door check

Google: site:cherokeeforum.com (enter search term(s) here)


ETA: sorry, fixed it....

1991Jeep_Man

Searching and hence google offers vague general answers, hence my post here. I know how search: I preach it to the newbies. I have yet to see a single google link telling me if I need a certain type of brake fluid resevoir/master cylinder for safe disc brakes, if the mentioned brake booster will be a DIRECT no mod swap, etc. The door... yeah, I probably could have gotten a link somewhere for that one. But since i had more than one question...

Radi

Yes. Unless you have the Bendix ABS, in which case you'll have to redo the lines.
I can't answer q's about the disc conversion as I haven't done one.

1991Jeep_Man

Will the rod need modified like with the WJ booster swap or is it really a true bolt in and go swap?

Thank you!

1991Jeep_Man

My main concern now is my stock booster and master cylinder. Being a '91 it has the single diaphragm booster with metal 2 section brake fluid reservoir. Will this need swapped?