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PostPosted: Sun Apr 24, 2016 8:59 pm 
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Joined: Fri Jun 12, 2015 9:25 am
Posts: 90
Location: new jersey
In this I'm going to show you guys what needs to be done to mount a 4gen brake booster to our Colts. It's a lot thinner works a lot better is easier to find and gives a space for running an aftermarket intake manifolds.which is great and you can do this mod any time no turbo motor needed. I did this on my car along with bigger brakes and new master before swapping a 4g63 in my car.

this is how it comes unmodified
Image
Image
First mod needed is to shorten the shaft that connects to inside linkage.
What i did is loosen the nut on the shaft all the way until you cant anymore by hand.
now put the part that the pin goes through up against the nut.dont tighten it as you only put it in to mark it where it needs to be cut.

after you cut it loosen the nut to clean up the threads.file the end where you cut or sand it or leave as is up to you.
after being cut
Image
with the bracket mounted
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Second mod is to shorten the ball end that go into the brake master cylinder itself. The way i did this was by putting the ball end on a drill and using a belt sander along with the drill spinning to make it nice and round.which is adjustable btw.
before
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ill get pics of the ball end modified after i redo this one. i did this to the first one this is another one i bought because i thought the one on my car was shot.




I cut mine a few times first time was still too long.
How you know its too long is if the brakes dont let go.too long and you have to shave some more off the ball end that pushes on the master.only way to fix it.

Too short and your pedal moves too much before actually braking. You can adjust the ball out to your liking. This is a time consuming process depending on how picky you are


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PostPosted: Wed Apr 27, 2016 11:30 am 
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Joined: Sat May 14, 2005 11:15 pm
Posts: 7515
Location: Stantonsburg, NC
Awesome job! Also there should be a way to take measurements and make calculations of how short to cut that nut with the ball on the end. You're right, if its adjusted too far out your brakes will drag and eventually seize up.

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93 Mitsubishi Expo LRV 1.8/manual
95 Eagle Summit DL Coupe 1.5/manual
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PostPosted: Tue May 31, 2016 9:59 pm 
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Joined: Sat Mar 12, 2016 2:01 pm
Posts: 29
Location: Boulder Creek, California / Kremmling, Colorado
I think I will be giving this a try. My wife's used to the massive brake booster in the taurus, our "motorsofa", and the little pedal pressure it requires to come to a stop. I'm imagining I should be able to grab some measurements off of the 4g15 hatchback booster and adjust the 4th generation booster to match. Is any bending or adjustment of the master cylinder lines required with the thinner 4th gen booster?


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PostPosted: Wed Jun 22, 2016 1:45 pm 
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Joined: Fri Jun 12, 2015 9:25 am
Posts: 90
Location: new jersey
I just pushed them back the front line needed a little persuading


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