Hi all,

Been making a mk5 servo fit, which means i can use the mk5 25.6mm master cylinder (because we can't get the bendix 25mm one anymore) which should help the brake pedal out ALOT over the commonly used xr3i 22mm jobbie.

Any way here are some pics of the bracket i made, will post the complete article up when the paint has dried,

Question for all that have done it, what outlets do i use from the master cylinder? I am using a front rear split with a willwood bias valve.











Cheers

Rob,

 

Looks good so far mate. I got my servo off the other day and was all set to have it painted but have now changed my mind and am getting a pedal box conversion thing. Much smaller than having a servo and also it has seperate master cylinder for front and rear brakes so if something fails i havent lost my brakes completely then lol.

 

Cheers mate,

I did consider a pedal box conversion but the car is going to be a road car and i quite like having a servo,

Any ho, literally just fitted the thing, looks right at home, just got to plumb it in.





You can just see my bias valve poking out on top of the inner wing,

Cheers

Rob,

 

Any one used this master cylinder before?

Rob,

 

What do you want to know? One outlet goes to a t piece and then to the front calipers, the other goes to the bias valve, then to a t piece and to the rear brakes.

Rick

 

lol cheers rick, just there are 4 outlets and wondered which to use and which to blank.

Cheers

Rob,

 

this make a big difference then?

 

Servo should help the brakes feel more 'modern' but i really did it because you can't easily (or i couldn't) get the correct sized master cylinder, the right master cylinder along with no abs should make the pedal nice and firm.

Rob,

 

Rob- my cars going to be a road car aswell mate. My reasoning for deciding to do the pedal box is it'll take up less space in engine bay and then i will also get braided lines. At moment i have the non abs set up with the proportioning valves or whatever they are in the engine bay, its cluttered and i want to create a bay with as little as possible. I must admit i dont know alot when it comes to brakes etc, i just go by what others do and looks or sounds good lol. Why out of interest do u want to run a servo? Not being funny, just literally wondering.

 

Good work Rob

 

try braking whist having your engine turned off thats what brakes feel like without a servo

 

why have you blanked them holes out with them metal strips mate?

can't you just change the end of the rod to push the different servo?

 

I havent blanked the holes mate, that was a trial fit of the plates i welded to my new servo mount. The new servo mount's studs were closer together horizontally and further apart vertically than a mk4's, i also couldn't bolt the mk5 servo to the mk4 mount.

So you can either be a pikey and drill new holes or adapt one of the mounts to make the servo fit, the rods are the same on a mk4 and 5 as is the brake bar.

Rob,

 

Cheers mate

As 12-second has said mate, roll down a hill and turn your engine off, pump the brake pedal until its hard and then try to stop.... you have to push bloody hard on the pedal often you won't be able to push hard enough to lock the wheels up.... thats what its like with out a servo, i can't comment on the compbrake boxes but loads of people use them to good effect.... but IMO only real benefit is more room under the bonnet and a better feeling pedal.

Rob,

 

Good point by 12 second and Rob, like i say im all new to all this and so dont know what to do. Ive right off the idea of pedal box thing now so im now back to square 1 not haing a clue what to do and have shit brakes.

Should i maybe do the same conversion as you then rob? I just dont have the knowledge that you have to be able to go modifying parts to fit.

 

Its alright mate, every one starts some where.

Do you still have ABS? and are you using standard disks and callipers? Im not saying a pedal box is shit as many people have them and like them... it just might not be the answer for you.

Rob,

 

I did this conversion on a MK3 Fiesta. I used the Fiesta transfer bar and servo mounts and shorted the servo push bar 12mm IIRC.

 

Was it worth while Muz? and which of the 4 outlets did you use on the master cylinder?

Rob,

 

Doesn't matter which you block off, either the bottom two or side two.

 

I didn't drive mine with it fitted but other people have reported it to be spot on inc. the lad I sold mine to. Doesn't matter which you use, just use which ever is neither for the installation I guess.

 

Cheers Rick and muz, just thought i would double check!

 

aah, bisto cheers for clearing that up

 

lol no worries

 

dont you just need to blank off 1 hole? you could use the front 2 outlets for left front and right front then for the rear just blank 1 hole and use the other to the bias valve then the t piece. this way you would only need 1 t piece.

 

this is the one i used same as in mk1 frs and if you had shortened your mounts by around 5-10mm rob then that would of had the effect of lenghtening your push rod and made you initial pedal feel more responsive as it would of took the slack out of the system which gives that sharp feel were all used to on newer cars but does not actually apply brakes if that makes sense and i used this to give me more servo as this again makes the brakes easier to apply and with the brembo's i run stops really well

 

Cool cheers mate, the rods were the same length on the mk4 and 5 but if the pedal still fells a bit spongy it won't be too hard to whip it out and weld an adjustable rod in. Think my servo is slightly smaller too as i seem to have a slightly larger gap between the strut tower and the servo. And how do you find your solid strut mounts? thinking about getting some but not sure if they will be too harsh.....

Cheers

Rob,

 

solid mounts are fine i'd recommend them to any one

 

Good stuff, been meaning to ask for ages, do you literally bolt your coilover straight up to it with no rubbers etc?

 

Rob- ive got rid of the abs yeah and i have cossie discs and calipers all round.

Project rs, that looks superb mate and sounds like what we all want. How much did all the parts cost and did u basically have to find a frs being broken?? Was there much modifying needed to make it fit to the pedal bar etc?

 

That servo looks like the ones in the mk3 mondeo so plenty of them floating about the place

 

I would imagine its more or less like mine to fit, what is shit about your brakes mate?

Rob,

 

correct it is also used in mondeo/transit/ fiesta/focus etc basically most of the newer fords use it and 99% have same size servo and master cylinder bore, just go on girlings site and the info is there, mine personally came of a 2003 mondeo td as it has hole for servo pipe on the same as ours where as focus hole is on other side and fitted like rob described and rob yes no rubber at all in my front setup as i have adj tca's to on rose joints too

 

Blimey rose jointed too, bet it sticks to the black stuff well with the adjustable tca and solid mounts,

My vac hole was also on the other side, just turned the servo round by 180deg

Rob,

 

Well just reversing it and then going forwards up and down the drive u had to push the pedal quite far to get it to brake, you could also manage to push the pedal right to the floor. And also since the car has been sat in garage a few months the brake fluid level in the reservoir is now near the bottom yet theres no patches on garage floor. I wonder if my servo and master cylinder are knackered.

 

Possible mate, you could be leaking fluid into the servo, i would be tempted to try a really good system bleed as it sounds like there may be air in the system, if your master cylinder bore is too small this can also give very spongy brakes in which case the above mod would definitely help you there,

Rob,

 

So on the new master cylinder pictured above, are the two outlets furthest from the servo for the front brakes? And the two nearest the servo for rear brakes?

I may upgrade to larger master cylinder to help with the escos calipers on front.

Will the cylinder fit onto late xr3i servo? Id rather not change it as I don't want one too big (I have a header tank quite close...)

 

By the looks of it, the cylinders mount diagonally instead of horizontal like the mk4.

The mk5 + mk6's look to be the same.

My questions still stand though.

 

Hello mate, i don't think it matters which outlets you use, both at the front seem to be connected as are the two at the back and you can't mount the mk5 master cylinder on a mk4 servo unfortunately.

You have to be careful which master cylinder you use as different models seem to have different bores.

Cheers

Rob,

 

so i'd need a mk5 servo, bracket and master cylinder by looks of it. how much bigger is the mk5 servo?

i have header tank mounted behind servo to the right where battery used to be so i have to run 2 water hoses past the servo...