I have a 94 XJ 2dr. I upgraded the brake booster and master cylinder to one out of an 01 XJ 4dr. Shouldn't it be a direct bolt in? The rod seems to be about 1/2" longer and is constantly applying pressure when hooked up to the brake pedal. Can the stop for the brake pedal be adjusted?

 

did you use the master from the 01?

if not, you will have to split them apart again and adjust the rod that goes into the master from the booster. it may take a few tries to get it right.

 

Yes, used both the master and the booster. Can the rod that goes into the cab from the booster be adjusted?

 

if it can, i don't know how. i've tried everything.
in one write up i read, that person swapped rods to have the shorter one.
me, i left mine with the longer rod. i got used to it pretty quickly.

 

I'm fine with the longer rod but because of the metal stop for the brake pedal and in order to connect the rod to the pedal i have to depress the rod about a 1/4" - 1/2" and that is applying the brakes and keeping me from rolling

 

oh, it's possible they changed the brake light switch/mount for 94. is your brake light switch bolted to the end of the pedal rod? did you have to grind your pedal rod flat on the end?
it sounds like you have the newer design where the brake light switch is mounted to a bracket under the dash, therefor stopping the brake pedal from raising up all the way.
you might just have to remove and replace the pedal rod with your stock pedal rod from your old booster... or cut and weld the longer one to the new length.

 

IF you swap in a 99-04 grand cherokee wj booster and master then you need to build some hard lines. you have to use a 3/16 spacer/washer on all 4 bolts tho. did the same in my girlfriends 94. by the time you get the rod shortened you would have the wj one in and working trust me i tried it.

 

i forgot about spacing it out.
you should be able to just remove the booster from the firewall and sliding some 1/4 - 1/2 inch spacers on the studs, then just bolt back up to the firewall. you might have to do something with sealing it around the brake rod.

that should get you rolling again.

 

Thanks for all of the suggestions. I got everything working now. I found a retaining clip inside the hole for the brake light switch that was causing the brake pedal to not return enough forward. I removed that and bent the bracket for the brake light switch forward and and re installed the switch and made my own method to secure it to the bracket. it works great now and my problem is resolved!!