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1965 Mustang Restoration: Dual Brake Master-Cylinder Upgrade The first step in the Mustang's restoration is a critical brake-cylinder upgrdade. From "Classic Car Restoration" episode DCR-501

A dual cylinder is safer and more effective.

In this first repair and upgrade procedure in the '65 Mustang's restoration, host Steve Magnante and Mustang specialist Allen Shepley remove the original single master brake-cylinder and replace it with a safer and more advanced dual master cylinder.

Whereas the original single cylinder unit controlled braking at all four wheels, the replacement has one cylinder dedicated to the front wheels, and one cylinder dedicated to the rear.This particular upgrade is essential and necessary as it could prevent complete brake loss due to a brake line failure.

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Steve prepares to upgrade the brake master-cylinder to a dual cylinder.

Tools and materials:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), some of the tools required for this project include the following.

dual master cylinder system
small siphon pump
rounded tubing wrench
residual brake valve
double flair brake lines
standard brake-line t-fitting
brake-line tubing bender

	Figure A
	Figure B

The early Mustangs, like most cars built before the 1967 model year, incorporated a single master brake cylinder. Our project car still has this original part (figure A).

In 1967 the federal government mandated an upgrade to dual master cylinders, because of problems related to single cylinders that could possibly lead to complete brake failure in the event of a damaged or broken brake-line.

The replacement called for a dual-reservoir master cylinder (figure B), with one reservoir devoted to the front brakes and the other devoted to the rear. That way, if there's any kind of problem at one of the wheels, the driver can still brake because the other half of the brake system still works.

Figure C

Thus, the dual master-cylinder is an essential upgrade in the restoration of any Mustang that hasn't already had the part replaced. To further enhance the upgrade, we replace the original part by installing a billet dual master-cylinder system that not only serves the purpose to improve safety, it's also lighter than the original, and it just looks good (figure C).

Steps:

• Under the car, disconnect the brake tail light electrical connection and remove the cotter pin so it's possible to detach the master cylinder push rod from the brake pedal.
  

  	Figure D
  	Figure E

• Use a small siphon pump to remove the brake fluid (figure D) before taking the old master cylinder out.

• When working on brass cylinder fittings, be sure to use a rounded tubing wrench instead of an open wrench which could damage the fittings.

• Remove the cylinder mounting bolts and the old master cylinder comes out.

• The dual master cylinder bracket goes in (figure E) and the mounting bolts are installed and tightened down.

• The first of the new master cylinder goes in, sliding the plunger boot over the push rod and seating the rod in the cylinder. The fasteners are installed loosely for now.
  
  
  
  

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  RELATED PROJECTS: 1938 Packard: Checking Brake System, Brake Hoses and Removing Master Cylinder 1938 Packard: Rebuilding Master Brake Cylinder 1938 Packard: Master Cylinder Installation, Metal Brake Tubing Demo 1938 Packard: Bleeding Brakes, Final Brake Adjustment 1962 Corvette Restoration: Brakes 1962 Ford T-Bird: Refurbishing the Drum Brakes

  
  

  ALSO IN THIS EPISODE:
  	1965 Mustang Restoration: Introduction and Initial Assessment
  	1965 Mustang Restoration: Mustang History and Resources
  	1965 Mustang Restoration: Body Disassembly and Prep
  	1965 Mustang Restoration: Dual Brake Master-Cylinder Upgrade