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post #1 of (permalink) Old 05-08-2005, 12:18 AM Thread Starter
 
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YJ Booster upgrade - Now no tail lights...

My brake light switch is not working properly after my booster upgrade.

It's one of those silly switches that is mounted on the pivot pin between the brake lever and the booster rod.

I can manually turn the tail lights on and off, by lifting the switch up and down.

I've got all of the bushing in the right place. I'll go scratch my head some more and try to figure it out... but any prior experience would be greatly appreciated.
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post #2 of (permalink) Old 05-08-2005, 03:48 AM
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Re: YJ Booster upgrade - Now no tail lights...

Sorry, no prior experience....

But maybe you can just bend the little flag that hits the switch a bit.

Often it's the easy things that become hard.

If not... sorry to intrude.

[img]/ubbthreads/images/graemlins/40BEER.gif[/img]
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post #3 of (permalink) Old 05-08-2005, 06:08 AM
 
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Re: YJ Booster upgrade - Now no tail lights...

did you check all the wire connections? i know that mine were alittle lose and every once in a while, the brake lights won't come on.

switch could just be getting old, so it may not react to the pressure from the pedal, but will work when you do it by hand
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post #4 of (permalink) Old 05-08-2005, 01:10 PM Thread Starter
 
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Re: YJ Booster upgrade - Now no tail lights...

Thanks guys.

There is no flag on this set-up. The switch is mounted over the booster rod end. The booster rod has a flat spot cut at about a 60* angle, where the switch base rests. The pivot pin goes through the switch and booster end with a bolt. The bolt is attached to the brake pedal.

Screwy system...

At first, I had thought the the change in angle when you depress the brake pedal triggers the switch, but now I think it is the "slop" in the pin/booster end assmbly.

The switch works fine when I force it with my hand to open up.

My '95 booster end had a 1/2" hole in the booster end. I had to drill this to 5/8" to fit the bushing. 5/8" is about 0.020" smaller than my '88 booster end. It was a pretty tight fit with the new booster, so I think that may by my problem - no slop...

I'll try wallowing out the hole a little bit and keep you guys posted.
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post #5 of (permalink) Old 05-08-2005, 01:56 PM
 
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Re: YJ Booster upgrade - Now no tail lights...

try lubing up the connection, i'm still thinking it's just sticky. i have virtually no slop in my pedal and my brake lights work.

by the way, what do you think of the braking after the swap?

does it make any difference if you press the pedal harder?

take a look at that cherokee posting, you might want to consider changing over to the other brake light connection.
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post #6 of (permalink) Old 05-08-2005, 04:03 PM Thread Starter
 
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Re: YJ Booster upgrade - Now no tail lights...

It was the slop, or lack thereof. That connection requires just a little bit of clearance, which I didn't have with the 5/8" hole (very tight to get the inner bushing in). I filed it out just a little bit to where the inner nylon bushing could easily rotate, just like it did in my stock booster arm and now it works.

Probably a better term would be clearance instead of slop.
The connection isn't loose, but it does have the clearance to engage the switch now.

I still haven't thoroughly bled the brakes, so I can't comment on the performance yet.

Here's a pic for those who haven't seen this ridiculous set-up.

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post #7 of (permalink) Old 05-09-2005, 08:39 AM
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Re: YJ Booster upgrade - Now no tail lights...

Whoever dreamed that up should be [img]/ubbthreads/images/graemlins/AR15firing.gif[/img]
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post #8 of (permalink) Old 05-09-2005, 08:55 AM
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Re: YJ Booster upgrade - Now no tail lights...

[ QUOTE ]
Whoever dreamed that up should be [img]/ubbthreads/images/graemlins/AR15firing.gif[/img]

[/ QUOTE ]

I'm betting that the guy was only hired because he is the nephew of the nitwit that spec'd out all of those Torx fasteners. [img]/ubbthreads/images/graemlins/frown.gif[/img]

[img]/ubbthreads/images/graemlins/40BEER.gif[/img]
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