Disc upgrade problems

I installed a disc brake kit on my Dana 27. No issues there. I tried to install the dual reservoir frame mounted master cylinder and have encountered problems. I had to cut out a piece of the inner frame to fit the mounting bracket for the master cylinder. No issues. I bench bled the master cylinder as per the directions. When I had to shorten the metal plunger substantially to fit the new master cylinder. I was unable to even mount it initially because the plunger was too long. Now that I have connect all the brake lines I pushed the petal to start bleeding the brakes and nothing. It goes straight to the floor. Any ideas? I removed the lines from the master cylinder, and plugged it up to try and re bench bleed it but nothing.

 

were all the lines replaced? if so your filling all the lines, wheel cylinders, and calipers. it might take a bit of fluid to fill everything again?

 

Sounds like a defective master cylinder if you can plug the lines off at the cylinder and you get no pressure.


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is it possible that rod is too long . and master cylinder stroke is off . not returning all the way back

 

I think I shortened the rod too much and now that the master cylinder is not under pressure, the rod cannot depress the cylinder enough. I'm not sure how to install the master cylinder with the stock rod though.

 

what bracket did you use for the master cylinder?
what year is the CJ? I am guess 66 and older

Couldn't you install the master cylinder, than put the push rod in the master-cylinder and attach to your brake pedal? I could see how leaving it attached would be an issue.

If you shorten it to much it can have some pressure or non at all. I swapped out master-cylinders and the new one needed a longer rod so I adjusted mine out. Prior to that I couldn't figure why I would loose my brakes.

 

Yes, knowing what bracket and master cylinder is being used may be helpful here.
Even If the Pushrod is a little too short it should still build some pressure unless full of air or defective.


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It is a '58 CJ5. I got the kit from www.kaiserwillys.com . The bracket mounts the behind the cylinder and and attaches to the inside of the frame. It seems to be similar to a mid 80s GM truck master cylinder. I tried inserting the rod from behind the cylinder. I adjusted the length as much as I could but was still insufficient to depress the cylinder enough.

 

Contact Hermtheoverdriveguy

He was supplying the kits to them with that style master cylinder. My understanding is they have since gone with another kit supplier (but this could be mistaken, I'd double check that).
I know the newer kits do not require cutting the frame and have remote mount reservoirs and come with the needed length Pushrod.


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Ok. I saw they went with a new style kit. Thanks. I will check with Herm.