I have finally gotten around to working on my 78 Bronco project some more. It is a 78 with a swapped 460 4 speed, dana 60 rear, and I am working on the front Dana 44 now. I have a Dana 44 HD (2 actually) from 76 highboys and am going to swap everything from the spindles out to give me the 8 on 6.5 bolt pattern I need to match the rear. (Can't afford a Dana 60 front yet.) This will also give me the big Ford 2 piston disc brakes on the front. I will be putting discs on the rear before it hits the road. The rear brakes need a total rebuild and it is almost a wash price wise to upgrade. I also discovered that the master cylinder and booster are also shot so I am looking for upgrade/ replacement suggestions.
I need something that will move a lot of fluid for 4 wheel discs and give lots of power for the assist. I am wondering about the older F350 hydroboost or other setups? Any suggestions of setups or things to research would be appreciated. I don't expect to be told what to do but I do want to dip into the vast pool of knowledge here for help to save me from a mistake that might make me a danger on the road if I screw it up.
My DD is a 2001 Excursion so I know 4 wheel discs are great. I may try to copy the master setup on that if no one has a better or cheaper suggestion.
Thanks in advance. Off to get the kid so I'll check back later and update if I forgot anything.
Here is the start thread (started by my brother when he had the Bronco before I picked it up) if anyone wants to check it out.
https://www.ford-trucks.com/forums/1...78-bronco.html

 

The rear discs should be bottom of your priority list. The front axle does between 60 and 80% of your stopping anyway (especially in a vehicle with a wheelbase as short as a Bronco). If anything, getting rear discs tweaked down far enough to keep from locking up the rears under hard braking will leave you with very little braking power to the rears anyway. (Which is why rear drums remained standard for such a long time. They stay adjusted, they are enclosed from the elements and they perform just fine in their capacity of 20-40% of the stopping power of most vehicles).

The best front brakes you can stuff under it are your best starting point. Love the idea of the twin piston calipers. As for the MC/booster, the OEM from the system that used the twin-piston calipers is probably a good direction to consider if for no other reason than fluid capacity.

 

I also should have mentioned that I am running 40 inch tires on the Bronco.
The biggest reason for rear discs is that I need EVERYTHING for the rear 60 brakes as it sits now anyway. It needs drums, shoes, spring kit, wheel cylinders, and new lines. I priced it and for about the same money I can do a disc upgrade.
I have been searching here and on other sites and find lots of info on the F350 brake upgrade. The problem is that is for single piston front calipers and drums (small wheel cylinders) in the rear. I am trying to find info on what master cylinder to use for a two piston front caliper and a single piston rear caliper, along with what booster. I realize I need to find something that moves a lot of fluid volume for these calipers. The OEM master for the system would be for drums in the rear still. Sorry for any confusion so far. Thanks for any help.

 

Some of the guys on fullsizebronco.com use the bigger piston T-bird calipers, F350 MC/booster & rear wheel cylinders with good success up to about 38s. Opinion seems to be with 40s & up hydroboost works far better than any vacuum booster, and really locks 'em up with anything smaller. There's several ways to go to hydroboost, some not even very expensive.

 

Thanks CS79bronco. I have been searching over there too. The Tbird calipers are single piston replacements for the stock calipers and the F350 setup is for rear drums with the 9inch rear end. I shall keep searching as well. Thanks guys.

 

I found a site with a step by step to convert the rear Dana 60 in my Bronco to the same discs as I am putting on the Dana 44 in the front. They are the brakes from a Dana 44HD or a Dana 60 front with the big dual piston calipers. I am still trying to figure out the master cylinder and booster setup. The brakes will be the exact same dual piston calipers front and rear. I know I will need an adjustable proportioning valve in the line to the rears but I am wondering if anyone has suggestions of what master/ booster setup to use? I am looking at copying the setup in my 2001 Excursion right now just because I am used to it and have it in the driveway to copy. The other suggestion I got was to use the hydroboost and master from a newer Ford Superduty F450 or F550 with the gas engine.
Thoughts from any of the gurus out there?

Here is the conversion for the rear brakes if anyone is interested.
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