knocking/clicking noise in brake pedal?

[Silverslk]

Whats up guys. My wife has been DD'ing the Bronco for the past few months (Honda needs a trans). Tonight she gets home and says the brakes are making a noise. Long story short, it comes and goes but there is a knocking type noise coming from the pedal/booster/master when pushing the brake pedal. I can't tell if its the booster or master and was hoping someone has experienced this before. If I do need to replace one (or both) of them, is there an upgrade while I'm there?

Thanks,
Andy

[Silverslk]

So, I searched over at FSB and if the noise continues (went away last night while looking at it) I will try the 1995 F350 booster/master in mine 1995. If I am going to buy one of those parts, might as well buy both and "upgrade" at same time.

[tcm glx]

Did you find anything on the actual clicking?

[philofab]

Maybe the bushings on the pedal itself? If it's coming from the booster, try unhooking the vacuum and see if it changes.

[Silverslk]

Tony, didn't find a thing.

Philo, I checked the bushing first thing. I noticed it if you look in the booster there the rod goes in there is some foam looking stuff. When it clicked/popped the noise came from behind that foam. Its either the booster or master and after reading up last night on FSB.....I'll replace both with the F350 units.

[philofab]

Check that the bolts holding the booster are tight and that the firewall is not cracked.

[Silverslk]

OK. I'll check tonight. Do these things have a problem with cracking firewalls? I had my neighbor hitting the brakes last night and could see the firewall deflect a little as he pressed the pedal but didn't think much about it.

[tcm glx]

I'll replace both with the F350 units.

Costs?

[Silverslk]

Checked autopartsplace.com and rockauto last night looks like ~$60 each

[Big Bastard]

Are the 350 parts a direct bolt in?

[philofab]

Are the 350 parts a direct bolt in?

Should be. Most that would be different is the fittings on the M/C due to year differences.

[BDKW1]

Check the seam between the firewall and the tranny tunnel. Mine had separated there and made all sorts of cool noises.........

[300]

OK. I'll check tonight. Do these things have a problem with cracking firewalls? I had my neighbor hitting the brakes last night and could see the firewall deflect a little as he pressed the pedal but didn't think much about it.

The 90's vintage trucks were notorious for having flexing cabs and you seldom see a pickup at least without a cracked windshield. The smallest rock chip turns into crack that races across the glass.

[PaulW]

I have seen pics on the forums that show lots of spider cracks where the booster mates with the firewall.
Paul

[johncharlesb]

They flex, Ford offered a retrofit reinforcement for the firewall for the clutch cylinder, do not know if they did for the master. It sounds like you have a popping as the two sides of the firewall crack separate when the pedal is depressed.

[tcm glx]

hey guys,
My brother took measurements, and with the coilover kit I have, I can not fit the brake booster upgrade.... any ideas or thoughts? Chris and Nick mentioned 90 degree master cylinder.... but I can not find those.

[PaulW]

hey guys,
My brother took measurements, and with the coilover kit I have, I can not fit the brake booster upgrade.... any ideas or thoughts? Chris and Nick mentioned 90 degree master cylinder.... but I can not find those.

=====
Consider my research:
www.abspowerbrake.com
The electic motorpump with their master. Pricy about 2x a Hydrotech or 5x compared to an Astro JY DIY setup. A HB sure wont fit in my Bronco due to the cage & spring tower.
Consider a JY HB with a canted bracket like we do on the early Broncos. I think if you cant toward the motor it wil be doable. The bracket design and fab will required some thought.

Paul