I've been working on and modifying Fords for 30+ years and yesterday was the first time I actually had my butt kicked by my car.This is the scenario,I converted my 70 over to disc brakes(front)larger drums in the rear.Changed master cylinder and put in a proportioning valve to balance the system.That was a big improvement but I guess I am spoiled with how all my newer cars stop so well with power brakes.I'm a firm believer in if you have plenty of GO you must have plenty of WHOA! So in my infinite wisdom I decided to convert to power.I just didn't like the look though of the Mavericks system with the booster pointed up and on an angle.So I fabricated an adapter to bring it down and staight out.No problem.Booster bolted right up,cut and threaded the rod out the back and modified the rod that attaches to the brake pedal so I can play with the stroke.Now comes the fun,I am using a cable for my clutch in my T-5.I had a set up but I am not happy with how it works plus it is now behind the booster. I've been chasing this around for a few weeks and yesterday I happened to find a pedal assembly from a fox body in the garage,took it apart and it slid right thru the bearing collars on my Mavericks pedal assembly.This is too easy I thought.So I squeeze my 260 pounds under the dash and start the install.Then it hit me,I can't see a thing.It went down hill from there.I'm trying to remove the wiper motor bracket because the quadrant is hitting it (had to cut and trim some clearence) Can't see the bolts,can't get my arms where I can turn a ratchet,cut my arm,bleeding everwhere because of my blood pressure medicine(makes my blood thin)getting dizzy from standing on my head.The dog jumped up in the car and decided to french kiss me when I wasn't looking.The mailman stopped by and decided to ask some dumb questions while I'm upside down creating new cuss words for this bolt that I thought was there but had actually fallen out and I can't get the socket on to tighten (it was on the floor under me).Just when I was ready to call it a day,everything fell in place.This will really work.The new quadrant lines up perfect with the existing hole for the accelerator cable,I'll have to move that.The cable exits the firewall about two inches from the booster.No binding and I can put on an adjuster in the old hole for the accelerator cable.All is well except one small detail.My master cylinder is to long now,it hits the strut tower.The only solution I see is cutting out a portion of the strut tower and welding back some reinforcement.Or finding a shorter master clyinder.Has anyone ever seen a short or shorter master cylinder from Ford.Disc/drum type? I would like to keep it all Ford if possible,but if I have to use another brand so be it. Has anyone else ever repositioned their booster before? Any thoughts would be appreciated.Sorry for the long winded explanation,I write like I talk,too much.
Sorry, didn't mean to laugh from your misfortune but that kinda snuck up on me. Couldn't hold back.Sounds like a great project though and I hope it all works out great...keep us posted.
The absolute worst place to work on these cars is under the dash. I always remove the front seat. I'm no midget myself. Makes things much easier for very little effort (4 nuts). I have seen a Geo set up used on Falcons which have even less room than we do. Check this link for more info: http://www.stuart.iit.edu/students/2112/restoration/powerbrakes.htm As you found out, the reason the stock booster assembly is cocked up and toward the center is because it dont fit any other way. Sorry, I was laughing too. (been there)
Thats OK Ray,I made it hard on myself for not taking the seat out.You know how it is though,you want to jump right in and work on the project at hand instead of planning things right.The other thing that whipped me good was removing the defroster plenum.You have to bend these little metal tabs to get it loose.I have got to get my eyes checked again!All you young guys out there,appreciate having good vision while you have it.It sucks wearing bi-focals.
Thanks for the link.I was wondering if you have to use the booster too,or if I can just use the master cylinder?I would hate to chuck all the work I've done on the bracket for the booster and start over.Maybe I'll go to the parts store and buy one to see if it bolts up.How do you guys find this stuff so quick? The internet is an amazing place isn't it?
I'm glad i'm not the only one who has those days. Getting older bites. I was in the salvage yard the other day and looked at a master cyl. on an Arrowstar, not sure what year, but it is a lot shorter.About a mid-90s w/o abs I think. Have you ever thought about a hydro-boost system? That is on my list of things to do!
I thought about the hydro-boost but I don't have power steering and I'm not sure if I understand exactly how they work.I will check the Aerostar master cylinder idea.
This one of those RARE times when I'm glad to be short ( Very rare !) When ever something needs to be done under the dash of our Mavericks, I get volunteered for the job. Even still, it's not easy to be doing a headstand on the drivers side floor with the brake and gas petal in your face, the steering wheel sticking you in the stomach and your knees hooked over the top of the drivers seat. Whoa! Does that ever paint a strange picture.
Oh man,,, yes it does suck doing work under the dash of these. You describe the install well, would make a great tech article for Shortorns, pics would add to it. The vision thing is getting me down too. I cant read sockets anymore, just me flying blind as usual. Dan
Did someone say....."HYDROBOOST"? http://www.maverickcomet.com/TechArticles/Hydroboost/Hydroboost1.asp
Been there, done that, but don't mind telling you it hasn't been in the last 10 years. And I WAS getting that strange picture...thanks!
