So last week i realized my brake lights were sometimes staying on after i got out of the car.
Did a little investigating and turns out that the brake light switch would sometimes come to rest against the back steering column bracket.
Must have been like this for a long time. You guys won't have that issue but because of how i installed the hydroboost 15 years ago, the eye hook was pointed downward about 30-45 degrees. In my defense 15 years ago there was no real off the shelf solution and honestly it seemed to brake just fine.
I was going to grind down the bracket (needed like 1/16 off the corner and it's crazy thick), but when i dropped the column down I changed my mind and it was suddenly time to install the MM kit that i've been looking at for years.
Pedal box went relatively easy (I took the entire column out of the car, which turned out for me was a necessity).
But holy hell, getting the hydroboost out with a 4v in the car was the worst thing i've ever had to do, period.
There is zero room. Lots of crows foot sockets, tons of smashed hands and using extendable magnates to get them when they drop.
Basically (and i'm oversimplifying) i took the bolts that hold the master cyl out and bent the mc out of the way (and can only go forward) and then pulled out the hydro unit. This is where removing the column (and having a car lift) comes into play, the lower bolt on the MC cannot be accessed from the top, i don't care how good or how small your hands are, not happing. The flaw in my plan was i already took out the hydro bolts in the car, the wrench didn't move far underneath so when i turned the wrench the booster turned and it couldn't be cracked loose. Luckily with no lower dash, no column and no pedal box it was easy to put the bolts back on.
The main difference in the kit is where the rod is attached to the pedal it's about an inch higher. I may have gotten away with just doing the pedal bracket, but i liked the idea of nice and neat and finished (something i was not about 20 years ago).
The hydroboost kit itself is fairly easy to install. If this were a pushrod engine, i'd guess it's 2 hours of work the first time around. My guess is i have 6 hours in it at 30 minute increments. I chose the walk away and come back fresh method due to heat and frustration. Normally i like one sitting, but in this case i most likely would have broke something. That big custom socket looks daunting, but that was about 1 minute worth of work with my milwaukee 1/2 impact. One thing i'll say is that i'm kinda surprise at how short the adapter plate studs are, they don't even sink all the way into the nuts under the dash and it's not really something you can mess up, the inside pedal box plate fits in formed holes that are already there and the hydro goes flush to the firewall. My guess is they should be a quarter of an inch longer.
Some other notes, when i did the column swap years ago, i repinned and replaced (you can depin the connectors so you don't need to crimp on the wires), which surely would have falling apart. I also redid my 25 year old headlight switch repair which was falling apart (would have failed if i drove at night), but again in my defense, back then all we had were junkyard connectors to replace already bad ones.
Another complication was that 15 years ago in my infinite wisdom, i ran the drivers side harness through the triple tree of hydroboost lines. No excess to pull, more crows feet to get them out (the hydro lines themselves a pain because of how they attach.
I realize not many of you guys other than Mike will want the hydroboost, but one of the nice things about is that it pretty much works with any brake caliper. I'll be going to radial mount calipers and soon as i figure out if i want to learn to powdercoat or pay to have it done.
I wish i took pics of the pedal brackets together, but it was 95 degrees and better pics were not on my mind.
Edit: And the car started when i was done, i disturbed so much under the dash and on the column, i was skeptical of that happening. Especially with the extra wiring going to the column from the 03 cobra computer.
