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the brake oil your using was it brand new or the right one? dot3-4 i dont know what kind ford truck require and dont know if it would do damage. if thebrake fluid you used was old and from a open can ?it might as catch humidity and therfor got contaminated
maybe damaging brake components.
just trying to help you
the gauge block Dennis shows on his web sight helped me a bunch. It was easy to make out of a piece of scrap aluminum plate i had laying around and now i know exactly where the rod is, .935 middle of spec shown in the diagram.
Can you make the brakes lock up without taking it for a drive? I would try and get them to do it again and unbolt the m/c from the booster without cracking any lines. That should tell you wether or not it's an adjustment issue.
Update----I took off the MC today and backed off that rod about 1/8" and already there was more play in the pedal and it wasnt locked up at the top. I didnt drive test it cuz i also had bought a new Driver Side Coil Spring Retainer and Pad(gallery pics) and was installing those until the bolts sheared off on me and now Im kinda skrewed. Ill try to drill them out tommorow and finish the install and then drive test the brakes. I really think that the pushrod adj. might do the trick.
did you replace the rubber brake hoses? check the brake booster also if the pedal stays down, if the old master leaked. the master probably leaked fluid into the booster and it will freeze the pedal down. you maybe able to pull it up. the brake hoses can collapse inside. fluid may go in, but not be able to flow back through.
A kinked hose would allow pressure to flow to the caliper and not back. I see no mention of the hoses being replaced unless the lines are including the hoses.
Yes--all the lines are new. New MC, hard lines down to the Valve, new rubber/metal line from Valve out to the front end adapter and new lines out to each caliper.
I just have to re-adjust the Booster rod next and take it for a few road tests. Ill update in day or two.
By the Way, I posted earlier about re-doing my Upholstery inside and just got my new kit from Fryers Auto Upholstery. I wanted something custom made and they did it for me with no upcharge. I didnt want the vinyl with the cloth inserts which is standard for the 78, but wanted All Black Velour with only Black Vinyl on the skirting. Check my Gallery in the next week for the Before/After pics. Its gonna be Shweeeeet!
Update--A couple days ago I took off the MC and screwed the booster pushrod back a couple spins. Im embarrassed to admit that it seems to have done the trick. DOH!!!
the brakes no longer bog the truck down after heating up and I get a better range of pedal motion now. I've had to adjust it a couple times because just a half turn makes a big difference in the pedal action/stoppage.
It only took me 3 months, all new brake lines, new MC, new Calipers, new brake pades, and 300$
however, its only been a couple drives and I havent taken it out on a freeway yet. Thats the ultimate drive test.