Dodge 3500 Master Cylinder Installed

[underDAWG]

Finally I replaced my stock TJ master cylinder with Dodge 3500 MC. It works beautifully.

It had been a struggle for more than 1 year since I switched to 35??s. My TJ did not stop the way it used to be, and the next stage of upgrade to 37??s is pending. While I was converting to Warn Full floater for my rear D44, I switched to Caddy rear disc also. Unfortunately, I didn??t notice any improvement on my brake performance. I then took the ??O-ring out, no observable difference. The pedal feel still made me uncomfortable. This went on more than 6 months. While there are many discussions on what works and work doesn??t. Unfortunately, there were so many contradicting results apparently due to many difference scenarios. There were great deal of debates on line pressure, proportional value, stroke volume and many other things. The debates are great and do enhance my understanding of my brake problem, but yet no viable solution for me until P4x4, Hunter from TX suggested me to use a Dodge 3500 truck MC.

I ordered a Dodge 3500 MC from the dealer. It turns out that the reservoir is too big for TJ, and most of the auto parts stores (Autozone, Advance Auto NAPA) do not carry one with the reservoir. Through BILLYCJ7, I got the part number form Bendix. I ordered mine from here: http://www.bendix-brakes.com/default.aspx

The installation could been easier; it was almost bolted in. I need to make a space about 7/8?? long. I used a 7/16?? bolt. The mounting holes on the Dodge MC is slightly bigger than the TJ MC mounting holes, so I put a couple O?? rings on the mounting studs so that the new MC will be centered. I also needed to grind the proportional value mounting bracket to clear the MC since its diameter is bigger than TJ MC. I bench bleed the MC and then bleed the whole brake system. I took a test ride, I couldn??t believe how nice the brake feel. Now the TJ handles like a BMW.

Here is the pic after the Dodge MC installed. On the right, it is the MC from the Dealer (reservoir is too big, otherwise everything is the same). I include the Bendix number too.



This pic shows the comparison between ZJ MC and Dodge 3500 Dealer MC. Dodge has is longer and slightly bigger cylinder.






BTW, I used to hate bleeding the brake system. With the Speed Bleeder, it is so effortless. Somehow, the trapped air is much easy to get rid of when compared to the wife/me method.

Later,
Linyee