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Master cylinder conversion - Power to Manual #59860
05/19/08 07:48 PM
05/19/08 07:48 PM
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440Jim Offline OP
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440Jim  Offline OP
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451Guy, to answer your question on the firewall reinforcement bracket when changing from a power brake unit to a manual brake master cylinder using the new style aluminum master, here are the pics of the one I modified:

A couple details that may be helpful to others.
1) You need the manual brake pushrod (as others stated)
2) I used a firewall reinforcement from a manual brake car, but you can drill the 4-bolt pattern into the power reinforcement. The car firewall has all the bolt patterns from the factory. You will also need to put the 1-5/8" diameter hole for the center of the master cylinder into the plate. It is lower than the power booster location. It actually intersects that old hole a little.
3) The brake lines will need to be bent a few inches to reach the new location.
4) I used 4 new 5/16 x 1.25" long bolts, to attach to the car. Self locking nuts are a good idea. I used the nuts that held the power brake booster on.
5) I readjusted the brake light switch, but it might have been fine as is. I moved it out of the way while I was working under the dash.
6) Throw away the power brake pivot linkage and short pushrod that connected to the pedal.

Re: Master cylinder conversion - Power to Manual [Re: 440Jim] #59861
05/19/08 07:51 PM
05/19/08 07:51 PM
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440Jim Offline OP
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The power brake plate was modified by cutting the hole to clear the lower location of the manual brake unit. I used a home made aluminum adapter plate to use the new style master cylinder, but they are available from several sources.

Re: Master cylinder conversion - Power to Manual [Re: 440Jim] #59862
05/19/08 07:56 PM
05/19/08 07:56 PM
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440Jim Offline OP
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And drilling the mounting holes for the adapter plate.

Re: Master cylinder conversion - Power to Manual [Re: 440Jim] #59863
05/19/08 07:59 PM
05/19/08 07:59 PM
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440Jim Offline OP
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Work in progress.

Re: Master cylinder conversion - Power to Manual [Re: 440Jim] #59864
05/19/08 08:06 PM
05/19/08 08:06 PM
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440Jim Offline OP
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440Jim  Offline OP
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A typical factory manual brake pushrod.

4438165-Brakepushrod.jpg (72 downloads)
Re: Master cylinder conversion - Power to Manual [Re: 440Jim] #59865
05/20/08 12:17 PM
05/20/08 12:17 PM
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MoparKansas Offline
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Skip this step.

6) Throw away the power brake pivot linkage and short pushrod that connected to the pedal.

List it on E-bay and say it is for an E-body. I sold one for $102.50 once...most of the time you will still get at least $20 for it.

Then 7)







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