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Thread: Running dana 60 ............ Braking help .............

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    Running dana 60 ............ Braking help .............

    Hey Guys

    Need some help

    Im running dana 60s front and rear on my 05 unlimited

    I dont have good brakes they feel spongy ...... maby I still have air in the lines maby I dont ??? .......... what upgrade master cylender can i run or will bolt in ?????? .... Hydro assist off an astro van???????????

    Any help would be awsome !
    Thanks !

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    hey thats a great question , i would like to know also
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    Assuming you are running 1 ton brakes with your D60's and you have not swapped masters, you will most certainly benefit from swapping to a master with a larger bore. The 2500/3500 Dodge Ram master swaps easily and if you can swing it, the hydro boost booster that is stock for that app works great, too.

    The problem is that the OEM master bore is too small and requires too much pedal travel to pump the appropriate volume to the callipers that are way larger than stock. The result is that the pedal modulation is out lunch and full pressure will never be achieved.
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    ok CDT Nut..... first of all Thanks ,

    second of all, this 2500 / 3500 dodge master , what years ??? and will i need to use the 2500/3500 brake booster ????????

    Thanks again !

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    do some research.. i believe 2000.. i went to a dana 44 and a 9'' rear in my yj.. and was thinking about the same thing.. are you running disc brakes in the rear? if so you can try residual check valves.. available at any speed shop.. they keep like 3lb of pressure in the calipers.. check pirate 4x4 they have alot of info on this

    http://pirate4x4.com/forum/showthrea...aster+cylinder

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    yea Im running Front and Rear disk... thansk ill check that out!

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    Quote Originally Posted by 05silverbullet View Post
    ok CDT Nut..... first of all Thanks ,

    second of all, this 2500 / 3500 dodge master , what years ??? and will i need to use the 2500/3500 brake booster ????????

    Thanks again !
    97 - Current have hydro boost. 94 - 96 have a usable master but a vaccuum booster which does work well but can sometimes be a tight fit in a jeep because of its OD. You do NOT have to use either of these boosters BUT you will want to swap boosters at some point as you will appreciate more power assist with the larger bore master than what the smallish jeep master will offer.

    As for residual valves, these masters have them already. However, the 94 - 00 Dodge master has a 10 psi residual in the rear which is a touch high for discs. It will work great BUT the rear pads will drag ever so slightly. 3-5 psi is a typical pressure for discs. 01- Current Dodge 2500/3500 masters are set up for discs front and rear.

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    I had the same issue with my old brake setup.
    D44's with elderado calipers in the rear.
    Went for residual valve front and rear, and a bigger master and Grand Cherokee DD Booster (you should already have one?). Still undesirable.

    So now I'm going hydroboost with my D60/14B.

    Also what Front D60? Ford, Dodge/Chev? Does it have a Dual Piston Caliper or a Large Single?

    You may want to get an Adjustable Prop Valve too.
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    I used one from a 01- Current Dodge 2500/3500 master. Bolt on application with a slight adjustment to the push rod. Did the trick for me.

    Ford 60 front with dual piston calipers and D60 Rear with the Chevy 3/4T front calipers that are popular for swaps
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    hey greg get on this site it will definatly help you and hear is the diagram.
    http://www.pscmotorsports.com/tech/i...hydroboost.pdf

    now i remember why i made the "y" i only had one port at the bottom and 1 on the side of the resivor that i had.
    Last edited by BadCompany; 02-09-2010 at 09:47 AM.

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    thanks a lot guys !!! there is a bunch of ideas here !

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    Quote Originally Posted by JKMotorsports View Post
    I had the same issue with my old brake setup.
    D44's with elderado calipers in the rear.
    Went for residual valve front and rear, and a bigger master and Grand Cherokee DD Booster (you should already have one?). Still undesirable.

    So now I'm going hydroboost with my D60/14B.

    Also what Front D60? Ford, Dodge/Chev? Does it have a Dual Piston Caliper or a Large Single?

    You may want to get an Adjustable Prop Valve too.
    these are the 60s outa tims s10 S10MUDDER befor he but rocks under it , Im running (REAR) front calipers off a one ton dodge , and the (FRONT AXLE) im runnin ford duel piston calipers .....

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    Have you solved this yet. Just want to know what works for future knowlodge and wisdom. I like brakes. So the more I know the better.

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    wow thats some big brakes

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    No, pretty standard 1-ton gear. What I got on mine. Well Chev Stuff.

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    ok so i have picked up a master off a 01 dodge 2500 .... same as 3500 , it bolts right up to the factory booster , and the stock lines will fit as well ! I have to extend the push rod a bit , will let you guys know when I get it anll hooked up,

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    ok I got the master on last night ... works great , clears the hood by an inch ! extended the push rod an inch , fired it up and it has great breaks as far as i can tell , I havent really took it out and stood on them ... but they feel %500 better than befor ! Very simple and easy way of gettin good brakes on thes axles for this application!

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    hey thats great to hear. hopfully ill see you on the trails.

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    Quote Originally Posted by 05silverbullet View Post
    ok so i have picked up a master off a 01 dodge 2500 .... same as 3500 , it bolts right up to the factory booster , and the stock lines will fit as well ! I have to extend the push rod a bit , will let you guys know when I get it anll hooked up,
    hey do you know if this master would bolt in to my 92 yj with some mods?
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