Brake booster upgrade question, 1991 XJ

loki_racer

Well-Known Member
Joined
Sep 7, 2005
Location
Pittsburgh, PA
I ordered the Crown Automotive DDBXJ1 from user AOR back in Novemeber. I just now got to installing it and seem to have run in to a problem. It isn't even remotely the same shape as the stock booster.

alh5.googleusercontent.com__9Rn6w6L3pIE_UXwKDfkHFKI_AAAAAAABQy5f1b2a5198b748395043446f678af11b.jpg

Because of this, the booster doesn't sit flush against the firewall because it doesn't fit.

alh4.googleusercontent.com__fNN1CRzfNO4_UXwJ0CwTv1I_AAAAAAABQy61e351709b5aa2ff0ecb8f79e06fd0a2.jpg

I looked at a couple other tutorials and nobody seems to mention this being an issue. Should I just bend that firewall piece out of the way? Grind it off?

It doesn't look like 4 Wheel Drive magazine had the same issue, but it's hard to tell what they did.

Any help is greatly appreciated. I've been without a Jeep, or really a car, for a couple months now.
 
You're on the right track, found this in your article. Second pic down on the left.

"The test fit revealed a flange in the way. A pair of sheet metal pliers made it easy to bend the flange upward, creating the needed clearance."

 
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