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Junkyard Update: 1994 vs 1996 front to rear lines

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Old Apr 6, 2020 | 08:42 AM
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From: East Tennessee
Year: 1996
Model: Cherokee (XJ)
Engine: 242 cui
Default Junkyard Update: 1994 vs 1996 front to rear lines

Looks like there were some changes in the brake and vent line routing between 1994 and 1996.
The 1994 front to rear brake line I pulled from a 1994 does not have these extra couplings:


1996 XJ Master Cylinder Brake Lines

However the fitting at the Master is 1/2" on both. I suppose using the 1994 line for a pattern to make from NiCu could work without those extra fittings, with room for easy adjustment.

The metal portion of the vapor recovery line terminated in a different place in the engine compartment in 1994 than 1996. The 1994 metal line enters the engine compartment, does a 90 across the firewall toward the passenger side, and terminates closer to the canister. In 1996 that last 90 is gone and a longer rubber line runs across the firewall to the tube.

Did not drag out the driver side caliper line I pulled to make a direct comparison, but that one seems different when it comes out of the wheel well and meets the flex line. Fittings are the same size.

The fuel lines are radically different. Don't even bother.

I did see where someone pulled the rubber back by the rail connection on a 1999 fuel line. Maybe my worries are misplaced. Under the rubber cover is a shiny black plastic tube that is a little flexible. Might be some grade of nylon? Anyway, seemed stout. I would still rather come up with a better hard line/flex line solution there. Similar to the repairs people did with rubber line, but in braided stainless.
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Old Apr 6, 2020 | 09:04 AM
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So that is what my '00 kind of looks like. Not a shot of mine but one I grabbed off the internet.


Those short pieces are not regular fittings. I am guessing bubble flare but not sure.
When I did the back drums on my '00 I replaced the long line from there to the brake hose on the diff. Also replacing that and the 2 out to the drums. All with the nicopp.
But I kept that short piece in the picture at the proportioning valve. I had to buy an adapter to connect a line with a regular fitting to it.
Those short peices were in excellent shape.
Going into my files almost positive this is what I used.

https://www.napaonline.com/en/p/WH_1...wordInput=1441

Now are all Jeeps with those short lines at the proportioning valve like mine?
​​​​​​​Not a clue.
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Old Apr 6, 2020 | 10:05 AM
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From the looks of your 1999, I was pulling parts from the wrong year. Should have just picked that 1999 apart, including fuel line from rail to filter.

Here is where the vapor line terminates on my 1996. In 1994 the metal line followed the path of that tube longer:




As it sits now, I will be replacing the front to rear hardline to nicopp. And all of the flex lines to braided stainless. (Rear across axle is stainless by Inline Tube and I highly recommend). The front lines are dirty, not visibly corroded. The front to rear line looks corroded in the back, as does the vapor line.

Driver's side inside the wheel well, the hard line has the same routing 1994/1996, but inside it takes some different turns.


1996 XJ Driver's Side

1994 XJ Driver's side hard line, flex line, and caliper.

Can anybody tell of this is an XJ original equipment caliper? Or, at the worst, identify it as some aftermarket brand?


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Old Apr 10, 2020 | 02:48 PM
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Pulled the furl line from a junk yard 1998 XJ. Was surprised there was an extra connector right under the front floorboard. Made removal without carnage a lot easier. The Northern Tool line tool (metal one) worked great again.

Now I understand how those stainless braided long flex lines can replace that. What I might do is have Royal Brass & Hose make up a metal one and replace the plastic portions with stainless braided flex with those same connectors on each end of the flex, do 4 connectors. For anybody wondering what is under that rubber hose at the fuel rail connection, this was a 1999 and I am not responsible for this carnage:


Rubber hose pulled back on a 1999 fuel line, fuel rail end.
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