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Brakes......still.

571 Views 40 Replies 6 Participants Last post by  inzane
'90 one ton axles, vacuum booster and 1.25" master. Before the rear disc swap the drums would always bite first, pedal height was normal when they were adjusted. The rear had a tendency to lock if I two footed the pedal.

Now equipped with Caddy style rear calipers, stock Dodge fronts. The front brakes were adequate prior to the swap, but never great. I replaced the master not long ago. All the front hoses were replaced but it's been 11-12 years. The calipers and slides look fine, bearings are tight. Rotors turned and new pads last year. Bled them several times.

The rears still bite first, and it feels like they are doing most of the work. Only now the pedal is lower, it takes one pump to get the pedal up to normal and the fronts to feel like they are doing much of anything. It does stop better with the one pump, but it still ain't confidence inspiring. Adjustable prop valve to the rear is backed way out, doesn't help. Pedal effort doesn't feel excessive. It just acts like the front isn't getting the required volume and pressure.

Yes, I've been considering the hydroboost swap, but that may not solve the lack of front brake circuit apply and pedal height. Might make it just take less pedal effort to lock up the rear. Hell there aren't many things it could be really. Volume issue, slack, flex somewhere, hoses, or master. Been fiddling with the brakes on this truck off and on for years, having a hard time pinning this one down. Tags are expired, need to get a state inspection and I doubt the one pump semi crappy brakes will impress them.

Got any fresh ideas?
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I would separate the lines and see if you are getting full pressure or comparable pressure to the fronts when compared with the rear. You will need a buddy. If you have a problem the adjustable prop valve may not be working correctly or the pressure is off on the master. I ran into this when I went to dual piston fronts on my rig, instead of the stock singles.

Neil
The disc/drum master probably doesn't move enough fluid volume to the rear circuit.

I would look for a disc/disc master that fits.
Switching to hydroboost should change the booster stud spacing and you have more options for a master. I picked up the M39309 master for an eventual swap - it fits 80's/90's Chevy hydro or vacuum booster, and 94-95 dodge vacuum booster.

Edit: I never evaluated Corvette or Cadillac masters for fit; same with 01+ dodge. Something else to check.
I picked up the M39309 master for an eventual swap
LOL, I ordered two of those last week for the same reason.
Another question. How are disc masters different internally from disc/drum masters? And how do they supply the required volume when the calipers and or cylinders have different volumes front and rear? It's probably been 25 years since I've had one apart, can't recall exactly what the guts look like. Aluminum piston, a cup spring or two etc. But what I do recall is never seeing one that wasn't a straight bore in regard to size.

I do realize that when a system is full of fluid with little travel required in the way of slack, the volume difference is incremental. But there is still a difference in volume required.
The main difference is in the reservoir. Some have differences in the length between, the pistons, or the front piston and the front end, which some say can affect the fluid volume, But I have not seen that from any reputable source.
While i haven't taken both types of masters apart for inspection.... I defer to piston areas and OE master/caliper pairing.

The M39309 master is a 1.34" bore and used with those front D60 Bendix calipers on all 4 corners. The caliper piston is 3-3/8" in size vs dodge wheel cylinders from 7/8 to 1-1/8" in size.
Joel...on the rear brakes hitting first...I'm wondering if you have the front line going to the front port on the MC, and vice versa? IIUC, the front line is supposed to go to the rear MC port, and v-v. No idea how big a thing that may (or may not) be...but maybe?
Joel...on the rear brakes hitting first...I'm wondering if you have the front line going to the front port on the MC, and vice versa? IIUC, the front line is supposed to go to the rear MC port, and v-v. No idea how big a thing that may (or may not) be...but maybe?
Well.....you made me wonder so I went to make sure I didn't have a brain fart. :) It's correct. Plain old 1.125" disc/drum MC with an equalizer hole drilled in the divider and a Wilwood prop valve on the rear brakes. Had the usual crap making the lines. Bought three double flaring tool setups, the third one wasn't junk.



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Did you do away with the factory combination valve? It has a feature that holds off the front for a few pounds of pressure to let the rear brakes move into contact with the drums.

Otherwise, I would suspect air or a blockage in the front lines. Or just plain cheap pads that do not have great friction.
While i haven't taken both types of masters apart for inspection.... I defer to piston areas and OE master/caliper pairing.

The M39309 master is a 1.34" bore and used with those front D60 Bendix calipers on all 4 corners. The caliper piston is 3-3/8" in size vs dodge wheel cylinders from 7/8 to 1-1/8" in size.

The disc/drum master probably doesn't move enough fluid volume to the rear circuit.

I would look for a disc/disc master that fits.
Switching to hydroboost should change the booster stud spacing and you have more options for a master. I picked up the M39309 master for an eventual swap - it fits 80's/90's Chevy hydro or vacuum booster, and 94-95 dodge vacuum booster.

Edit: I never evaluated Corvette or Cadillac masters for fit; same with 01+ dodge. Something else to check.

Wouldn't happen to have a link to a load of highly useful dimensions on stud spacing, mounting register OD's etc?
I'll fax you a cold beer if you do.
I think those are trade secrets. Several years back I searched, emailed, and got nothing. That would be a good thread, I have a handful I could measure and start a list.
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Did you do away with the factory combination valve? It has a feature that holds off the front for a few pounds of pressure to let the rear brakes move into contact with the drums.

Otherwise, I would suspect air or a blockage in the front lines. Or just plain cheap pads that do not have great friction.
Yessir, combo valve is yanked. I've bled these things pale, including with a home brewed pressure bleeder. I don't think it's a blockage, they function just not very well. They also don't drag like they would if a line was a bit plugged, and it doesn't pull to either side when braking. I bought the best pads they had, but that means little these days in the way of parts house stuff. But even cheap pads wouldn't cause a low pedal. I also turned the rotors while doing the brakes.

It's a bit odd George. I was riding around the neighborhood with a laptop a couple weeks back, tinkering with the trans and doing repeated stops. When I pulled into the carport the front brakes were hot as a pistol and smoking a bit. I was of course doing the one pump Polly on those stops. But the dang things just don't feel like they're doing much. When it comes to a full stop I can feel that the rears are the ones doing the majority of it, especially if I don't pump them.

Once stopped, at a light for instance, I have to pay attention to keeping a bind on the pedal or it can actually start creeping forward even though the pedal doesn't bleed down. I sometimes rest both feet on the pedal if it's a long light. Despite that the pedal effort isn't higher than it should be, as in the booster is bad. The things just don't bite and if I unconsciously back off a tiny bit at a light it creeps. A new side effect of a 4" crank and low 1st gear ratio. 4LO would be a real hoot.

It's possible I suppose that the master has some sort of an internal issue. But I've worked on cars for nearly 50 years and I've never seen a braking system act like this one does. The answer may be to throw the whole system in the junk and start from scratch.
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Wouldn't happen to have a link to a load of highly useful dimensions on stud spacing, mounting register OD's etc?
I'll fax you a cold beer if you do.
Sorry no.... just trial and error.
I would separate the lines and see if you are getting full pressure or comparable pressure to the fronts when compared with the rear. You will need a buddy. If you have a problem the adjustable prop valve may not be working correctly or the pressure is off on the master. I ran into this when I went to dual piston fronts on my rig, instead of the stock singles.

Neil
What did you do to correct it with the dual pistons?
It's a bit odd George. I was riding around the neighborhood with a laptop a couple weeks back, tinkering with the trans and doing repeated stops. When I pulled into the carport the front brakes were hot as a pistol and smoking a bit. I was of course doing the one pump Polly on those stops. But the dang things just don't feel like they're doing much. When it comes to a full stop I can feel that the rears are the ones doing the majority of it, especially if I don't pump them.

Once stopped, at a light for instance, I have to pay attention to keeping a bind on the pedal or it can actually start creeping forward even though the pedal doesn't bleed down. I sometimes rest both feet on the pedal if it's a long light. Despite that the pedal effort isn't higher than it should be, as in the booster is bad. The things just don't bite and if I unconsciously back off a tiny bit at a light it creeps. A new side effect of a 4" crank and low 1st gear ratio. 4LO would be a real hoot.

It's possible I suppose that the master has some sort of an internal issue.
couple thoughts, if the rod Between the booster and master is too long, it could be blocking the fluid from returning to the master. You could loosen the master, and put a washer or spacer between the master and booster, then test drive it. Or just loosen the front line at the master after driving it to see if there is retained pressure.

B, a bad master, that is retaining pressure in the front line.

I am leaning more towards the bad master theory. I had two rebuilt ones from the parts store that did the same thing with mot releasing the front brakes. Since then, I only buy new ones. But I may go back to rebuilding them myself.
The callous on my head is starting to bleed again from banging it on the wall. I think it's past time to throw a hyrdoboost and bigger disc master on it and then work my way out from there if that doesn't do the trick.

I doubt the stocker has the right volume and pressure required because that would be far too easy.....so what do I need in the way of a PS pump? Preferably one that will bolt to LA brackets and is compatible with my current V belt pulley.
Another application I thought of is 99+ E350 van. These are rear disc.

That would be a good thread, I have a handful I could measure and start a list.
Same here.
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Cheby used the same PS pump, it just had a two inlet reservoir, and a slightly higher relief spring. Many do the conversion by using a T on the return line, and nothing else. Back in the day, cheby diesel owners used to convert to vacuum boosters because of the HB's leaking so bad. I guess they got the leaking fixed, you do not hear about it any more. I left a couple of hydro boosts behind in Pa, Not sure if Tony, or Dan grabbed them.
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Cheby used the same PS pump, it just had a two inlet reservoir, and a slightly higher relief spring. Many do the conversion by using a T on the return line, and nothing else. Back in the day, cheby diesel owners used to convert to vacuum boosters because of the HB's leaking so bad. I guess they got the leaking fixed, you do not hear about it any more. I left a couple of hydro boosts behind in Pa, Not sure if Tony, or Dan grabbed them.
I was reading Sam's conversion threads from '09 and '14 this morning. One for Oxx which was diesel and the other is Homer's rig. Homer's is a Mag block engine so I wasn't sure the pump they used on his would fit. But if my stock pump will do the job with maybe just a reshim of the relief valve.......cool. :cool: Let the parts gathering begin.
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