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65 coupe 302 stock rebuild AOD conversion
For my winter project I decided to do a power front disc brake conversion
What I purchased
A Wilwood four piston kit with 11 inch slotted rotors
A 7 in.² dual diaphragm power booster from a 92 mustang
Master cylinder with an inch and an eighth Boar from the same 92 mustang
10 pound residual valve in the rear line with an adjustable proportioning valve
Mustang Steve brake pin relocation kit
What I did
Installed kit bench bled the master cylinder adjusted the booster rod to master cylinder measured my vacuum from the intake and I’m running 18 HG at idle
Bled the system in the correct order passenger side rear driver side rear passenger side front driver side front
My problem
When the car is not running I have a good stiff peddle as soon as I start the car The brake pedal drops about 4 inches and then slowly bleeds off to the floor rebleed the system. Same conditions
The only thing that I do notice is when I put my foot on the break with the engine running I can hear the engine RPMs change I also tied in a vacuum gauge to the booster line and I’m pulling 18 HG‘s at idle if I put my foot on the break it drops to 15
Any ideas would be great thanks
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When I installed Wilwood calipers on my 65 Corvette, I had a problem getting a proper pedal. It would go to the floor after bleeding everything. It turned out the caliper pistons were stuck in their bores. (From being new, not that there was anything wrong. They just were not engaging with the pressures available after bleeding). The fix was simple. I just stomped hard repeatedly on the pedal to apply enough pressure to move the pistons. All was good after doing that. I only mention this since you are using Wilwood calipers.
I think your 1-1/8” master cylinder will be too large and not develop proper pressure to operate the brakes. Foxbody master cylinders have two different size pistons in them and are typically avoided. A 1” bore tandem master cylinder like the 92 Ranger disc/drum unit would be more suitable.
The only thing as far as another suggestion is that you have a defective booster. The MustangSteve booster system is designed to use the single diaphragm 9” (four cylinder engine) booster (but the v8 booster such as yours can be used).
Typically if a pedal acts on its own, the booster is defective.
Also, and this is typically never a problem, be sure your brake pedal can return to its upper static position without its travel being limited by a rubber stop or anything else.
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