1-Ton axles on D2, Master Cylinder Issues

[ChicagoDII]

I am putting a D60, Sterling 10.5 axle set under my D2. When I swapped from D2 axles to FZJ80 stuff I had no issues with the brakes, the FJ80 calipers work well with the D2 master cylinder. Since the new 1-ton axles have much larger brake calipers I am going to assume I need to swap in a new master cylinder to push the massive pistons on these Ford axles.

I really dont know much about brake systems, so I hope someone on here can help me out. The F350 these things are off of use a 1 3/8" master cylinder. I went to Napa and they had an 04 F350 master so I went and checked how it would fit under the hood. The D2 master is only about 4" long coming out of the booster, the F350 master is about 10" long, and interferes with my coilovers. Right about here is where I need help. I know that I need a master that is at least a 1.25" bore or a 1 3/8" bore, but most of those are as large as the F350 master. Does anyone know of a master cylinder with a large bore, yet a short overall length?

[Buckon37s]

Hook everything up and run with it for a while. You may be surprised. I am still running a stock rover mc with a D60 front with no issues. I run 40's too. I thought I would need the swap and found a good candidate to be from a Chevy corvette. Don't plan on doing anything to it in the near future.

I think you will out weigh me by a few thousand pounds so you never know.

[ChicagoDII]

Originally Posted by Buckon37s

Hook everything up and run with it for a while. You may be surprised. I am still running a stock rover mc with a D60 front with no issues. I run 40's too. I thought I would need the swap and found a good candidate to be from a Chevy corvette. Don't plan on doing anything to it in the near future.

I think you will out weigh me by a few thousand pounds so you never know.

A 57 Corvette, right? I think thats what Aaron is running on his and he says his brakes dont feel that good.

Will the size of the brake lines make a difference, I assume it would, but i dont know the engineering behind that one. Anyone with a F250/F350 superduty want to measure brake lines?

[madcowdungbeetle]

Swap on 1/2 ton calipers.

Problem solved.

[HandBuilt]

Master from a 197? Chevy C65.

Pretty small OAll length. 1.25 inch bore IIRC...

PS the size of the brakelines makes absolutely no freakin difference.

[Jtisdale]

I too kept the stock master cylinder. I used the LR calipers on the rear 9" and use 1/2 ton calipers on the front 9/60. Brakes work well with the 37 krawlers/beadlocks which are much heavier than the 37 MTRs/steelies I use to run around on the street with.

It might be easier to go hydoboost if the brakes don't work that well for you than cram a big master in a tight spot.

[isabellaclarke]

Why not just go hydroboost. I run a 94 chevy 2500 hydro unit and MC. on my 60/14bolt. It's a tad long, but not as deep and it locks ups the 3/4 disc all around with ease. You could even go with an astro van hydroboost since its quite a bit shorter...and i believe the same legnth as the ones Vanco sells.

if you're planning hydro assit, may as well go ahead and order from Van...because there' not enough flow for both unless the hydroboost unit is ported.

[darkstar]

x2. I have a vanco hydroboost. works well, lots more room under the hood.

[mongosd2]

x3 on the vanco hydroboost...did you gut the rest of the abs system out yet? Aaron's needed 2lbs residiule valves...

[darkstar]

I eliminated ABS entirely. I have a hydraulic filter for the steering system and the prop valve for the brakes where the ABS modulator used to live.

[mongosd2]

I also gutted the abs system...using 2lbs residual valves on the stock MC

[What Rd.]

To those who swapped axles in a D2,

What did you do about the wheel speed sensor signals? If you eliminated them, how does that effect speedometer readings and how the transmission shifts?

[PTSchram]

Originally Posted by What Rd.

To those who swapped axles in a D2,

What did you do about the wheel speed sensor signals? If you eliminated them, how does that effect speedometer readings and how the transmission shifts?

If you eliminate them, you will not have a speedometer.

[Discosaurus]

Speed-o-meter ?!?!?!?
You guys have been DRIVING to the trailheads too much.

[krazz1e]

on my other pos d1, my rover axles with 35" stopped terribly, with same MC on 1 ton axles, braking improved consierably with the stock MC and abs outta the picture.

With that said, I was told by a rover mechanic that the dII mc is better than the dI. But what the fuck do I know?

try it and if it sucks then worry about it, you may be suprised.

[What Rd.]

1. I knew that about loosing the speedometer, but was really wondering if anyone has done anything to duplicate the signals. (I know, I should have said so in the first place.)

2. I drive to the trailhead in my PS with whatever trail truck on the trailer. (-insurance for getting home)

3. Little more info on D2 MC: 99-02 is different than 03-04 MC-they changed the MC and front calipers in '03. Not real sure why someone would say the D2 MC is better than a D1-they both leak!

[ChicagoDII]

Got it driving and I have no brakes at all. Would adding some 2lbs residual valves into the system help it until I figure out what master to use?

As for the master, the 03 F350 one is too big to fit, anyone want to recommend another 1-ton master cylinder?

[isabellaclarke]

I've seen a stock RR master used on a Toy Booster that seemed to work OKish...but I'll say again...hydroboost is 100% the way to go.
The corvette MC is also good....but most 1 ton MC are large. I use a chevy 2500 MC. I had to make a bracket to space the entire hydroboost unit/MC down about 3 inches and weld a new pin on the Brake pedal to get it to clear the hood (not on a rover)...so you may need to get creative.