just got a 25mm non abs mc for my mondeo brake servo conversion and have notice the servo is shorter than an abs version even shorter than an original rs turbo one will this be ok as thought you needed more volume to work bigger brakes like the cosworth ones I have

 

What brakes are going onto the car?

 

has cosworth 4x4 fronts and standard series 1 rears

 

I was going to ask what part number your brake master cylinder and servo have on them to see whether you are running an S1 setup (or whether I am!). Are the original servo and MC in the car?

My car has 4x4 Cosworth brakes with S2 rear drums on what I assume to be a stock MC and servo with braided lines. In all honest the car stops fine and right on the button. No long pedal and for Escort standards it actually comes to a halt! Remember that the Cosworth brakes have a 60mm piston as did the S2 RS Turbo calipers, so the pedal travel will not as long as you think. Going to a bigger master cylinder in some cases can actually reduce braking power but give you a nicer pedal.

I noticed this going from my Wilwoods TBH. Many suggested for me to go with a smaller master cylinder to get around the issue ; the pistons in my Wilwoods were 31mm, way smaller than the Cosworth item even with the surface area of 2 pistons combined.

 

its still on the 22mm mk3 original mc and servo but the pedal goes nearly all the way down and dosnt fill me with confidence

 

I'll check the part no.s on mine. It could be as simple as a seals being shot in the master.