[TMessick]

Originally Posted by Calpantera

I decided to add some fluid to the M/C to see if the calipers leaked (It was empty on that side) and then I pumped up the pedal. Now the pedal has no travel. I had converted the car from an automatic to a 4 speed so I checked that I had the rod in the right hole on the pedal and it is in the upper hole. I then unbolted the M/C from the firewall to see if it had a deep pushrod hole and it appears to because I could not get the rod to clear the M/C. I am just going to yank the M/C since I am replacing it anyway. My question is does anyone know what the correct rod length should be? The old auto pedal assembly that I took out looked to be some bastardized cobbled together thing and I am not sure if it has the right rod. I think I left the rod in the donor car when I got the pedal assembly.

Thanks!
Bill

Manual brakes "should" use the deep hole master cyl -- the deeper hole helps keep the pushrod from dropping out when you lift off the brake pedal quickly. As far as how long the pushrod should be, I'd adjust it until the pedal is high enough to trip (off) the brake lamp switch and just barely touch the upper pedal stop, but there should be no "preload" on the brake pedal (if the master cylinder piston can't fully release, you can end up with brakes dragging, so you need to have a little clearance/slack in the system)