If anyone with a 4.9 is looking to upgrade their brakes, I found a great, fairly inexpensive way to do it:

The hydro conversion is the best mod I have done on my truck since changing from the gashog 390 to the 300! It was fairly inexpensive, and I have unbelievable stopping power now!!

I used the unit out of a 92 astro van ($40 at the bone yard), the supply lines from a 1990 Super duty ($15 ea. at Rockauto). I also changed the master to one from a 92 F350 s.d. 4x with 4x disc for my rear discs. Some guys have done it using a modified oem master, but with the added psi, I didn't want to risk the master taking off like a missile. I also changed the p/s pump to a Saginaw for the needed psi. Others have stayed with the oem ford p/s pump.

Now I feel like I'm in control of the truck again. It is amazing the stopping ability once more.

This isn't the master I ended up with, but you can see the hydro.

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And here is the Saginaw p/s pump. There is one unit, made by A-1 Cardone, which is a bolt in replacement for your ford unit. It never came oem on any vehicle. It is a conversion from the GM Sag. unit made to convert to the Ford bracket.

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I also found a trick for bleeding. I know this will freak some people out, but it works great and saves time. I no longer bleed the calipers! When the line I disconnect is vertical, I simply squirt b.fluid back into the line before I reconnect it, then bleed BOTH front and rear simultaniously at the nearest junction for the first few pumps of pedal, and you're good to go! Why pump air through the entire system by bleeding at the cals? It is fast, easy, and saves time. A few little squirts of b.fluid with an ear syringe, etc., and presto! (I know I'll get some outrage over this, so bring it on!!).

 

I forgot to post a photo of the master I ended up with: 92 Chevy C3500 , 4X4 with 4X disc. Since that year and model came with 4X disc, and only the hydro brakes, nothing needed to be modified. I tried the Ford of that year, but the mounting was different.

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It's on my to do list, while I have down time for hernia surgery. Hydro is the ultimate in braking. I have 4 wheel drums now, and will be swapping in 12.5" F250 disc up front and a Sterling rear with 12 or 12.5 drums. I already have a saginaw pump from a van.

 

I have the complete brakes off my d.60. I'll give you a good price if you can use them. PM me if interested.

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Im looking into this mod and i understand how it all comes together. im just wondering what to do with the brake lines that lead to the ford master cylinder, the threading is different on the astrovan/c1-3500 so how would i go about adapting the ford brake lines?

 

Weatherhead makes all the tubing nuts to fit the GM masters.