Brake issue! !!

but now I believe I'm going to buy a brand-new proportioner valve that matches the 96 booster and master cylinder

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The proportioning valve that you already have is the same one that you would buy. It's fine, it will work fine.
 
At this point everything is torn out and I hook the booster up. just didn't know exactly where all the brake lines went to the proportioning valve and the MC I checked it out online and I think I have it will get back to you guys thanks

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I explained how to hookup the brake lines to the proportioning valve in an earlier post.
 
At this point everything is torn out and I hook the booster up. just didn't know exactly where all the brake lines went to the proportioning valve and the MC I checked it out online and I think I have it will get back to you guys thanks

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The rod should be coming out of the booster. I also have a 91 and was wondering if you can snap a pic before I rip into mine. Someone up above mentioned that the 91 model rod looks slightly different so I'm curious.


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I already installed the booster the rod measures from the base of the booster to the end 5 3/8 and that will hook up perfectly with the 91

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The rod should be coming out of the booster. I also have a 91 and was wondering if you can snap a pic before I rip into mine. Someone up above mentioned that the 91 model rod looks slightly different so I'm curious.


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With my 91, the brake light switch was on the pedal mount and not the rod like all the howto's seem to have. I think it was 98 booster I used and didn't use the spacer and brakes work well. Little soft for me but it may just be the old lines needing replacement or how it worked vs newer brakes.
 
Yeah I didn't need to hook up the brake switch either the same as yours which made it a lot easier and I use no spacer just a little thin piece of cardboard seems to have a good feel in the pedal

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Yeah I didn't need to hook up the brake switch either the same as yours which made it a lot easier and I use no spacer just a little thin piece of cardboard seems to have a good feel in the pedal

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Cardboard? Isn't that right against the firewall where water could come down? I have a leak at the blower mower which is in a similar location on the other side of the engine bay. Worried about it degrading/leaking?


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Yeah it's a pretty tight fit but you're probably right probably get some type of gasket membrane for it

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Here is what the original ABS '91 master cylinder shaft looks like;
20160908_121057.jpg
 
Here is what the '91 brake switch assembly under the dash looks like;
20160908_121137.jpg


This pic was after I installed that POS Crown set up. You can see where I had to move the shaft pivot point on the brake pedal assembly.
Yes, I know the weld looks horrible. It was very windy that day and it was blowing the shielding gas away. Besides, it was a press fit so the weld was just extra insurance.
 
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Yeah I just went to O'Reilly's and bought a 96 booster and a 96 master cylinder the booster had no problem hooking up with the brake pedal no modifications whatsoever. I'm just waiting for my friend to help me flare some tubes and get everything together

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This is what the booster to firewall gasket looks like;
20160908_120844.jpg

It is made of 1/4" thick closed cell foam. I acquired some from a local upholstery shop and made my own.

20160908_120916.jpg


20160908_120928.jpg

I know it's not pretty but nobody can see it once it is installed, lol. I had to make 2 because I used the spacer. There is enough adjustment in the brake switch that you probably don't need the spacer but it doesn't hurt to use it.
 
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Here is the whole mess (ABS system) after it was pulled out. It's all good if anyone wants it for free. The pump was a little weird but it worked.
20160908_121103.jpg
 
I have everything up I just had a buddy of mine that's going to help me get the proportioner valve hook up I'm not that familiar with bending brake tubes So and I've been working a lot but hopefully this weekend thanks for reply

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