At this time in the process we need to get under the dash and access the interior side of the pedal assembly. This is much easier if you pull the drivers seat out first.
Bolt the drilling template to the pedal through the original hole and then use a pilot drill bit to start the new hole in the upper position. Finish the new hole by drilling out to 8mm diameter. Remove the clevis from the booster and thread it onto the new pushrod, be sure to include the jam nut as well. Mount the Honed firewall adapter to the firewall and fix it in place with the factory nuts from the inside. Insert the new pushrod from the engine bay side and attach to the pedal with the clevis and original pin hardware.
Push pedal to the floor so that the push rod is extended through the adapter, then offer the new master cylinder up to the pushrod taking care to ensure that the push rod is engaged into the master cylinder correctly. When test driving this new set-up keep in mind that manual brakes will be more dependant on the brake pads and rotors being up to temperature for effective braking and that it may be necessary to allow additional stopping distance for the first few stops when the brakes are cold.
Results 1 to 8 of 8. Join Date Jul Here's how! Install your new manual brake master cylinder, most likely after fabricating your own custom adapter bracket to fit the new master cylinder to the firewall.
I don't have any pictures of the one I made for the old big block truck, but it was basically a piece of heavy gauge steel with 8 studs welded to it, 4 on each side, one in the bolt pattern of the firewall, the other in the bolt pattern of the master cylinder.
Reconnect the black line to the port for the front circuit on your new master cylinder, and reconnect the red line to the rear circuit port. This will allow you to retain RWAL while going to manual brakes. This allows you to continue to have the warning light that tells you when your brakes failed.
Going all out: This ones for you Dave! This method uses some bits from a Chevrolet S pickup and some good old hot rodding modifications to get the job done. The bottom line is that when you want to change your vehicle from one configuration to another, start by looking to see if your vehicle was ever available with that option during its production life.
This works for brakes, transmissions, engines, rear axles, even seats. There is no reason to re-engineer the vehicle when factory replacement parts may be available that bolt right in and are designed to work together. Image courtesy of Wikipedia. Your email address will not be published.
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