Brake Pedal Height?

[Tbird6]

In the middle of my disc brake conversion. Unfortunately I did not measure my brake pedal height from the floor before I took everything apart. Research shows most cars are in the 6.5"-7.5" range but that seems too high for the Squarebird pedal?

5.5"-6.0" looks about right and the pedal travel should be in the 2.0"-2.5" range.

There is a threaded rod between the booster and the pedal so I can put it where I need to.
Looking in the shop manual I find no specification for this?

Can anybody measure theirs?
Thanks for any help!
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[simplyconnected]

Here is the official Ford Service Manual procedure:

image.png

Now, here is MY unofficial procedure. It works with no need for technical, fancy, or expensive tools:

Remove the cover on your master cylinder and look straight down. You will see two small holes, one on the floor of each side. These are fluid 'return' holes for when you let off the brake pedal and the piston returns.

Unbolt the master from the booster. You can leave the brake lines attached if they are installed. We're not cracking any hydraulic lines.

The booster's output has a jack screw with a jam nut. If a helper eases down on the brake pedal, that jack screw will become more apparent. During this procedure, only press the brake pedal to adjust the jack screw.

When mating the master and booster, you are looking down the hole for slight movement of the piston to partially cover the hole. That means, the jack screw must be extended far enough to just touch the master's piston. At that point, tighten the jam nut. If you adjust the jack screw out too far, fluid will never return to the reservoir. Tighten the master to the booster and you're DONE.

Don't worry about pedal measurements from the floor. That distance will take care of itself when you're done and the brakes will feel good. Remember, the pedal has some adjustment where the rod pivots at the pedal. - Dave

[Tbird6]

Thanks for the reply and the shop manual photo's but that's not what I am asking about?

I have the ABS Power brake Booster/MC combo. After talking to them the push rod you mention and what is documented in the shop manual has already been set to the correct position by ABS when the combo MC/Booster was assembled by them. I do have that tool if I need to adjust the rod.

The problem is the brake push rod from the pedal to the booster is adjustable. This means you can set the pedal height where you want it. That is a handy feature but since I did not measure the brake pedal height BEFORE I took it all apart. I don't know where it should be.

Maybe a picture will help?
Here is what ABS sent with the above combo. This rod goes from the brake pedal pin to the brake booster linkage. Note it has loops on both ends so no rotating the rod with it in position.

ABS Brake Rod.jpg

Note the adjustable threads and lock nut. How long should this rod be? Well that depends on the brake pedal height off the floor. The next problem is with the change in MC this rod MUST be centered in the hole that is in the firewall. Again I have a problem as it appears ABS made the rod wrong. The eye on the left end of the rod needs to be longer to place the rod in the center of the firewall hole.

Now I can connect the 2 pieces but the rod is at an angle and it needs to go thru the firewall flat so the rubber firewall boot can be installed. This is not needed on the stock set-up as the MC bolts directly to the firewall and seals the hole completely.

I was searching for an adjustable brake rod that could be adjusted while in place. RH threads on one side and LH threads on the other. Like how you adjust tie rods.The setup I have now requires one end to be removed. Adjust the threads and re-assemble. Then check the pedal height. This is VERY time consuming and imprecise.

I was hoping to find something like this? The one pictured won't work because it has a loop on only one end. If mine was built this way it would be a simple adjustment that you could make while the brake rod is in place. Just spin the rod to adjust the pedal height.

Adjustable brake Rod.jpg

Here is a labeled picture of the firewall where the Booster/MC mounts showing the problem.

Firewall Hole Alignment.jpg

I have fabricated a modified brake rod and it now does go thru the hole flat and I need to determine where to set the brake pedal height This is a design error on the part of ABS and I will talk to them about it. They have been responsive but after 2+ months I am still trying to get the correct rubber firewall boot that is shown in their catalog on the MC/Booster combo. So not sure they will help.
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[simplyconnected]

ABS sells two different models, one for a Lincoln and the other for a Squarebird. This wouldn't be the first time they sent the wrong one. The first time that I can remember, they sent a Lincoln kit to one of our members in Australia. Shipping charges are terrible. After many ignored emails and phone calls from the buyer, I got involved and spoke with one of the owners. He finally made good on his sale.

Call ABS and tell them that your kit doesn't fit. It looks to me like the offset on your pedal rod isn't enough. Squarebird master cylinders have a very low firewall mount, causing the new firewall bracket to raise the booster about five inches, just to clear the steering column. - Dave

[Tbird6]

Thank you Dave. I also thought this should fit without modification. I have talked to them 2 or 3 times already. But that was about the combination valve and we got that all squared away. I will call again.

Here is what I made compared to the one ABS sent. Mines on the bottom obviously.

Modified Brake Rod-Compared to ABS Version.jpg

It just looks wrong?
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[simplyconnected]

...It just looks wrong?.

It does not look wrong. The 'hockey stick' end looks correct. I don't know if I would trust that butt weld. I would like to see the rod welded across the whole bottom. You should be able to stand on your brakes without consequence. - Dave

[Tbird6]

Sorry. No I meant the extra high loop I made. All the other brake rods have a small loop. So why do I need this tall version? Again maybe this points to the booster bracket geometry being wrong?

Yes that was a spot weld to check if the dimensions were correct or not. Then I will weld it fully.
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[simplyconnected]

...So why do I need this tall version? Again maybe this points to the booster bracket geometry being wrong?..

image.png
Because that is how the rod reaches the firewall bracket's center pin.
Remember, your new firewall bracket raises the booster quite a bit, like 4".

But ABS should have supplied the correct kit with the correct brake pedal rod for a Squarebird.

When you finally get the right firewall bracket, adjust the 'link' so that the top is close to the firewall. (You'll see when you get there)

There are three adjustments:
The brake pedal rod (inside the car).
The booster's input clevis.
and the booster's output jack screw. - Dave