Has anyone who has done a 10 bolt/Dana 44 to Dana 60 swap found it necessary to upgrade to a 1 ton master cylinder?
Here is what I am working with, got the 60 installed, put on brand new calipers, pads and rotors, and new stainless extended brakelines.
I popped the top off the master cylinder, and suprise! I found the rear reservoir empty. Like bone dry empty, no brake fluid residue or anything.
My rear drum brakes don't show any visible fluid on them anywhere from the outside, and neither did my master cylinder, so I can only assume that sometime somewhere before my ownership of the truck, something happened. But who knows when....
The truck always seemed to stop fine, and never had any problems with it, so I guess I been running on front brakes only for a while.
So back to current issues, I bled the front brakes, bled both reservoirs on the MC and bled the front brakes again. But the pedal feels real soft.
I am quite certain that the rear brakes need to be bled to, but I never noticed the pedal feel this soft before and so I am wondering if I need to upgrade to a 1 ton MC?

The pedal will be softer with the stock 1/2 ton MC bore and 1 ton calipers and drums, simply a fact of hydraulics. Provided you get the air out of the lines a larger bore MC will firm up the pedal.

i got quite the oposite out of my truck, i have a 85 k5 blazer and with the half tons all the brake hardware was new and the pedal would grab like 2 inches down which was fine never had any problems stoping now with the 14/d60 in there the truck starts to stop at like a inch down and this thing will lock up the tires and stops way better then it did with the half tons. so i didnt have to upgrade the mastercylender thank god. just make sure you have those rear brakes adjusted, before i did that the pedal was going about 3/4 of the way down

you need to bleed the rears before you can see whats happening.

the proper way is to start at the farthest wheel from the mc and work closer. start at the back and than do the fronts.

your 1/2 ton mc is fine. you could upgrade but the benefits are minimal imho

Well I drove it today (low speed) after bleeding the fronts and the master cylinder and it don't wanna stop for shit.
So I will bleed the rear brakes and replace my blown out wheel cylinder before I do anything else I guess.
Thanks for the help.