This past weekend I finally deleted the abs from my 91 Limited. Unfortunately I think I picked a bad vacuum booster from the jy as my pedal is still soft as ever til it gets about 2-3 inches from the floor. The brakes however are still noticeably better than before. I'm planning to get another booster probably a re-manned one from parts store. Rebleed and double check everything again.

The real issue that I have is a noise that developed during my first quick test drive. It started after my second hard stop attempt, as a rythmic clang like a coat hanger rubbing a tire and hitting under the truck and got worse til it is a pretty harsh clunk that gets faster as the truck does. It sometimes goes away when i accelerate but coasting or stopping its def there. I parked it behind the house til I get home off the road this weekend to go over things.*

I'm wondering where to start looking as I haven't read of anything similar unless it was tcase or ujoint related from wheeling and mine was parked all weekend. Could it be a loss of vacuum through the booster screwing with the vacuum actuator/switch on the front axle or tcase? Or did I miss something in the abs other than the mc, pump & control unit under the seat?I tried to be very careful not to disrupt anything during removal of the abs parts under the hood but, maybe I missed something? Or rather snagged something.*

Any ideas of what I should look for when I get back home will be greatly appreciated as its my daily driver and I need it back up and running asap.***

 

Look to see if your exhaust pipe is touching the trans/transfer case crossmember, or very close to it. Indication of bad motor and trans mounts.

 

Thanks. I'll definitely look into that. Wouldn't have thought to go that route after working with the brakes.

 

Once again thanks for the info. Turns out I just got in a hurry to beat the rain putting it back together and pushed a brake line out of place. It was knocking against a ujoint in the front drive shaft. I did get the mounts changed out anyway as the were shot to h3ll!!