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Old 10-04-2019, 01:42 PM
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8.8 swap brake system setup

Ive been looking into swapping the 8.8 into my 94 yj on 33s. And Ive read about changing out parts so that the brakes work with all disc setup. Whats the best solution for this.


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Old 10-04-2019, 02:10 PM   #2
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YJ proportioning valves changed over the years i think 1991-1995 were the same though. If you have the later style proportioning valve it should work fine with discs in the rear. The TJ's with disc brakes in the rear used the same proportioning valve as later YJ's and TJ's with drum brakes. If you have a Early 1987-1990 YJ things might be different not 100% sure.
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Old 10-04-2019, 03:41 PM   #3
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Second what agalloch07 said. I confirmed this with Blain at Black Magic Brakes.

All this talk of needing to push more fluid because of the rear calipers and needing a bigger bore master cylinder is rubbish. I foolishly listened to all these people and installed the Ford Grand Marquis MC with its 1.25” bore and it did nothing but make the brake pedal effort greater.

The best setup for stock front brakes and the Ford rear end is the 95 YJ 4.0 double diaphragm booster, or modified TJ booster, and the corresponding stock 1.0” bore master cylinder.
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Old 10-04-2019, 05:41 PM
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Originally Posted by vmxwinn View Post
Second what agalloch07 said. I confirmed this with Blain at Black Magic Brakes.

All this talk of needing to push more fluid because of the rear calipers and needing a bigger bore master cylinder is rubbish. I foolishly listened to all these people and installed the Ford Grand Marquis MC with its 1.25 bore and it did nothing but make the brake pedal effort greater.

The best setup for stock front brakes and the Ford rear end is the 95 YJ 4.0 double diaphragm booster, or modified TJ booster, and the corresponding stock 1.0 bore master cylinder.


I have the 2.5L, will this setup still work?


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Old 10-04-2019, 07:11 PM   #5
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Totally agree with the above post, the dual diaphragm booster was night/day difference. I picked mine up off Car-Part.com for $65 delivered. You have to make new hard lines from proportioning valve to master cylinder


1992, 4.0,5 spd, BDS 4.5 heavy duty lift, jb conversions ss sye, 8.8 with ARB, Aussie front, tj shafts, dual dia.brake booster, 33 bfg a/t
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Old 10-04-2019, 07:47 PM
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Totally agree with the above post, the dual diaphragm booster was night/day difference. I picked mine up off Car-Part.com for $65 delivered. You have to make new hard lines from proportioning valve to master cylinder


1992, 4.0,5 spd, BDS 4.5 heavy duty lift, jb conversions ss sye, 8.8 with ARB, Aussie front, tj shafts, dual dia.brake booster, 33 bfg a/t


So all you did was add the DD booster? Same MC and prop valve?


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Old 10-04-2019, 08:01 PM   #7
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When we swapped mine over to the 8.8 we replaced the booster and the master cylinder with OEM replacements from NAPA just to make sure we were starting off on the right foot so to speak. My YJ stops super quick and it takes very little peddle. The e-brakes are where some of the trouble is with the swap but there are companies that make the necessary parts/cables. It's a huge comfort to know I have disc brakes all the way around and they are working properly. The previous owner of my Jeep did not take care of the rear brakes and it was very dangerous.
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Old 10-04-2019, 08:30 PM
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Originally Posted by wookiedave View Post
When we swapped mine over to the 8.8 we replaced the booster and the master cylinder with OEM replacements from NAPA just to make sure we were starting off on the right foot so to speak. My YJ stops super quick and it takes very little peddle. The e-brakes are where some of the trouble is with the swap but there are companies that make the necessary parts/cables. It's a huge comfort to know I have disc brakes all the way around and they are working properly. The previous owner of my Jeep did not take care of the rear brakes and it was very dangerous.


What year is your yj? So are you on a stock setup, just new?


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Old 10-04-2019, 08:42 PM   #9
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So all you did was add the DD booster? Same MC and prop valve?


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Same proportioning valve, master came with booster


1992, 4.0,5 spd, BDS 4.5 heavy duty lift, jb conversions ss sye, 8.8 with ARB, Aussie front, tj shafts, dual dia.brake booster, 33 bfg a/t
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Old 10-04-2019, 08:46 PM   #10
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1992, 4.0,5 spd, BDS 4.5 heavy duty lift, jb conversions ss sye, 8.8 with ARB, Aussie front, tj shafts, dual dia.brake booster, 33 bfg a/t
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Old 10-04-2019, 08:46 PM   #11
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1992, 4.0,5 spd, BDS 4.5 heavy duty lift, jb conversions ss sye, 8.8 with ARB, Aussie front, tj shafts, dual dia.brake booster, 33 bfg a/t
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Old 10-04-2019, 08:49 PM   #12
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What year is your yj? So are you on a stock setup, just new?


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Mine is a 93 and yes, just a stock set up with new parts. It does have the dual diaphragm. I will try and take some pics tomorrow.
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Old 10-04-2019, 08:55 PM
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Same proportioning valve, master came with booster


1992, 4.0,5 spd, BDS 4.5 heavy duty lift, jb conversions ss sye, 8.8 with ARB, Aussie front, tj shafts, dual dia.brake booster, 33 bfg a/t


What should I look under on car-parts.com to find the DD booster? And will it work on a 2.5L?


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Old 10-04-2019, 09:30 PM   #14
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What should I look under on car-parts.com to find the DD booster? And will it work on a 2.5L?


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I believe 94-95 years but dont quote me on that? 95 for sure. It should work regardless if its 4 or 6 cyl.


1992, 4.0,5 spd, BDS 4.5 heavy duty lift, jb conversions ss sye, 8.8 with ARB, Aussie front, tj shafts, dual dia.brake booster, 33 bfg a/t
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Old 10-04-2019, 10:10 PM   #15
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Dual diaphragm boosters were used on 1994 YJ's with anti lock brakes. But they might be different than the 1995 dual diaphragm booster because they have different part numbers. In 1995 dual diaphragm became standard on all 4.0 YJ's and they are the boosters commonly swapped. The 2.5 1995 YJ's used standard diaphragm boosters all of the older YJ's used.
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Old 10-05-2019, 12:36 PM   #16
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Old 10-05-2019, 12:43 PM
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How much did it cost for new parts? Do you have the part #s


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Old 10-05-2019, 01:37 PM   #18
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I'll have to ask Pops, he was the one that changed it all. I'll see him tomorrow evening and can get more info.
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Old 10-05-2019, 05:32 PM   #19
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When we swapped mine over to the 8.8 we replaced the booster and the master cylinder with OEM replacements from NAPA just to make sure we were starting off on the right foot so to speak. My YJ stops super quick and it takes very little peddle. The e-brakes are where some of the trouble is with the swap but there are companies that make the necessary parts/cables. It's a huge comfort to know I have disc brakes all the way around and they are working properly. The previous owner of my Jeep did not take care of the rear brakes and it was very dangerous.



I used my original cables and cable adapters from The Flop Shop Offroad. They work great and they are cheaper than replacing the cables. I am running 5" of suspension lift and factory YJ cables are the perfect length. https://theflopshopoffroad.com/colle...cable-adapters
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94, 4.0/NV4500/NP231HD w/JB Conversions super short SYE, 4.5" Rubicon Express lift, JKS 1.25" body lift, Dana 489's w/OX lockers 4.88 gears, Tom Woods drveshafts, 35" BFG KM3's, WFO boomerang shackles, Warn XD9000 winch, Doug Thorley header, JBA mid pipe, Borla cat back.
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Old 10-05-2019, 05:57 PM   #20
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I used my original cables and cable adapters from The Flop Shop Offroad. They work great and they are cheaper than replacing the cables. I am running 5" of suspension lift and factory YJ cables are the perfect length. https://theflopshopoffroad.com/colle...cable-adapters


Forgive me if this stupid but does this replace the adjustment portion around the drivers side? I had to Gerry rig that section with a bunch of washers- doesnt work well haha


1992, 4.0,5 spd, BDS 4.5 heavy duty lift, jb conversions ss sye, 8.8 with ARB, Aussie front, tj shafts, dual dia.brake booster, 33 bfg a/t
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Old 10-06-2019, 06:48 AM   #21
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The cables that came with my 8.8 from the previous owner were these: https://eastcoastgearsupply.com/i-49...ke-cables.html I didn't realize they were $100 but they work. Pop had a little trouble getting them installed but they work great and I have no issues parking on a hill.
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Old 10-08-2019, 07:18 PM   #22
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8.8 swap brake system setup

Have this rear in my 1990 YJ. Tried many things to get the e brake to work but still it don't hold.There are a lot of post's online about this problem.I have red that you must use the Motorcraft brake shoes as they are a little softer.I purchased my axle from east coast gear and all the brake parts are new inc park brake shoes and cables,but I am sure they used aftermarket shoes .I will probably try the dealer shoes next (60 bucks or so).I should mention that I had to eliminate my e-brake pedal due to a full cage install and are using a pull handle which puts less pressure on cable but it should still work. Just be ready for a potential e-brake issue.

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