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Old 02-06-2002, 10:17 AM   #1 (permalink)
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ABS to non-ABS conversion

hey guys,

I am faced with the unenviable task of repairing my brake system on
the Millenium Falcon (1990 RR).

The ABS pump whines and whines and whines, and I have a serious brake
fluid leak, having to top it off about every 3rd or 4th day. It
takes FOREVER to build up pressure, and the braking isn't solid
enough to even lock up the tires.
I KNOW that it'll cost a fortune to replace the pump, and I also think that the block that routes the fluid has some serious problems, so I don't want to keep fixing a problem I know will just continue to be a problem.

SO.....

I have sourced a COMPLETE pedal assembly and brake assembly with the
vaccum boost. It even has all the wires and brake sensor. Basically
I told the wrecking yard to remove the ENTIRE brake pedal and master
cylinder system and I bought it for $200.

It's been sitting in the shop for about 6 months, and now I have some
time to devote to it.

Has anyone done this before? I have an idea of how I'm going to pull
it off, but the ABS system has a different brake line routing pattern
vs. the non-ABS system (discoS1).

No one around here has done it, and no one has heard of anyone doing
it. Before we break fresh ground on this I thought I'd ask.

Thanks! (and sorry again for the T-or-D stuff)

Michael
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Old 02-06-2002, 12:39 PM   #2 (permalink)
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What did the pedal assembly come off of? An NAS DI?

what you ideally should use is an 88 or 89 rangie. this way you maintain dual circuits to each caliper in front. (87 would have lockheed MC which needs a different pedal and booster than the girling)

Just bypass all the ABS stuff with new hard lines and run a T to the rear or something to get the signle line set up on the 88 or 89 to a dual line like the abs 1990 . You might be wise to replace the proportioning valve with the earlier one as well.

With a disco I brake assembly you need to figure out something else as the MC is designed for single circuit front brakes. Does this make it unsuitable, probably not, but it does mean you need to run a t to both front calipers and make sure it is proportioned correctly. On the plus side it is set up for two lines to the rear.

Also NAS DI is ABS, but different than the RR system.

You might be better just bypassing all the ABS you have now and fixing the leak. Or even repairing it. usually only the accumulator is bad which when not fixed kills the pump. The weak brakes are most likey due to the leak which is letting in some air.

Good luck! I just replaced the Disco I's MC (at 5years old) and have gone though the rangies and the 110s. Brakes suck!

Ron
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Old 02-06-2002, 02:55 PM   #3 (permalink)
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Brakes do suck.

The brake assy. came from an NAS D1.

I don't mind having the single circuit brakes to the front. In fact, I'm thinking of running Wilwood calipers to the front.

The proportioning valve will be replaced by a Willwood one with a pressure guage.

Thanks for the tips, they will be useful.

Michael
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Old 02-06-2002, 05:39 PM   #4 (permalink)
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Then no problem. Just run a T in line somewhere to get the single line to the front.

If you REALLY want to do it right I would recommend replacing all the hard lines with stainless steel. You will be changing so much already why not. Its a bit of a PITA to work with but you do it once and you are done. Thats what I did on the 110.

Ron
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