DIY Network

Drum-to-Disc Brakes Conversion, Part 3 Master-Cylinder, Brake Booster and Distribution-Block Upgrades From "Tricked Out" episode DTRK-210

	The Honda Civic's brake assembly has been replaced with newly reconditioned parts salvaged from an Acura Integra.
	To accomplish the brake master-cylinder upgrade, the brake power-booster must be swapped out as well. The two boosters are essentially identical in appearance and function except for the manner in which they connect to the master cylinder. The Honda version (LEFT) has mounting bolts aligned horizontally, while the Acura's are oriented horizontally.

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In this episode of Tricked Out, host Andrew Totolos upgrades the brakes on a 1997 Honda Civic with a restored disc-brake system salvaged from an Acura Integra. He has already made the switch from drums to disc using a mix of new and salvaged Integra parts. However, in order to take full advantage of the upgrade, the car's brake master-cylinder must be upgraded as well. In part 3 of this project, Andrew swaps out the Civic's master cylinder using a new Acura version that utilizes a larger working piston. To ensure compatibility of all components, he also swaps out the brake booster and distribution-block with comparable Acura parts.

Materials used in this episode:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), tools and materials used in this episode include:

Salvaged Acura disc-brake assemblies
Slotted rotors
Replacement brake pads
Brake master-cylinder
Brake power-booster
Brakes distribution block
Degreaser
Brake cleaner
Braided steel flex-lines
Sandpaper
Wire brush
Masking tape
Wire hanger
Caliper paint
Drop cloth
Brake fluid
Small bucket
Clear hose
Clear bottle
Line wrenches
Pneumatic tools
Floor jack
Jack stands; wheel chocks

DIY Difficulty Rating for This Project: We gave this a difficulty rating of 4 on a 5-point intermediate-level scale.

Safety Alert: Always wear eye protection and ear protection, and follow proper safety precautions, when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.

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	Figure A
	Figure B

Though the brake assemblies have been swapped out for the salvaged parts, our brake-system upgrade isn't finished just yet. In order to take full advantage of the newly modified setup, we'll need to swap out the Civic's master cylinder for an Integra unit (figure A). Acura's larger version pushes more brake fluid through the lines for enhanced braking power.

But because the replacement part has slightly different configuration than the Civic's original, we'll need to do a swap on the brake booster as well (figure B). The brake master-cylinder and booster work together to convert the pressure you apply with your foot to more than 1000 PSI of stopping power at the brakes. Under normal circumstances these are parts that last a long time. Since we don’t know what kind of shape our donor car was in, it’s a good idea to use new or refurbished parts instead of salvage items here.

Replacing the Master Cylinder

• To begin the swap, unplug the two sensor wires that run to the master cylinder cap (figure C).

• Remove the vacuum line from the power booster and tuck it out of the way (figure D).

  Figure C

  Figure D

  
  

• Use a line wrench to remove the two hard brake lines from the master cylinder (figure E).

  Important: Brake fluid can damage your car's paint. If you should spill any, be sure to wipe it from any painted surfaces immediately.

• Use a long extension socket to loosen the two nuts holding the master cylinder to the power booster and carefully remove the master cylinder (figure F). Set the old master cylinder into a bucket to catch any spilled liquid.

  Figure E

  Figure F

  
  

  Figure G

• Pull the throttle cable from the bracket located above the power booster (figure G)

• Back out the bolt holding the bracket in place.
  

• Next, go inside under the dash, where the brake pedal meets the firewall, to unbolt and release the power booster. Remove the nuts that hold the power booster on with a deep well socket (figure H), and loosen the push-rod lock nut with a wrench (figure I). Use pliers to unscrew the push rod from the yoke. With the fasteners removed, the original booster can be removed from the engine compartment.

  Figure H

  Figure I

  
  

• Set the remanufactured power-booster into position in the engine compartment (figure J).

• Go inside the car and secure the booster by tightening the nuts finger-tight.

• Line the yoke up with the threaded push rod and thread them together with pliers.

• Tighten the lock-nut down. Add the remaining nuts and tighten them down also (figure K).

  Figure J

  Figure K

  
  

• In the engine bay, replace the bolt that holds the bracket in place, and then push the throttle cable onto the bracket (figure L).

• Set the master cylinder in place over the output rod (figure M), attach it to the power-booster with lock washers and two nuts and tighten down securely.

  Figure L

  Figure M

  
  

  
  

• Install the vacuum line to the power booster, and then pull it across the bracket and push into place (figure N).

• With the booster and cylinder installed, we also need to replace the brake-system distribution block. In the brake system, this part functions to ensure that the brake fluid is distributed equally and in the correct portion to each of the brake assemblies. Since the Civic version is designed for use with rear drum-brakes and a smaller master-cylinder, it will need to be replaced with a part compatible with the newly upgraded system. In our case, we replaced the old block with an Acura Integra version (figure O) designed to work with disc brakes all the way around.

  Figure N

  Figure O

  
  

  
  

• Remove the hard lines from the old block. Start with the two lines that ran to the old master cylinder. (These can be recycled with the rest of the leftover parts.) The remaining lines will be reused, so be careful as you bend them back away from the block. Most importantly, avoid creasing the lines. To prevent creasing, try not to bend the lines more than a little bit in any one place.

• Once all of the lines are removed from the distribution block, remove the two bolts holding it to the firewall (figure P).

• Replace the old block with the refurbished Integra model and bolt it in securely (figure Q).

• Move the lines from each brake into place and tighten them down.

  Figure P

  Figure Q

  
  

  
  

• Once the brake lines are installed, the master cylinder lines can be attached. Since the fittings on the new master cylinder are on the opposite side, the original hard lines won’t fit. However, steel braided lines (figure R) can be custom ordered based on an eyeball measurement before you begin. The new lines are tightened down using a 10mm line wrench (figure S).

  Figure R

  Figure S

  
  

  
  

Important: Included in this summary are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of upgrade-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs or upgrades, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

RESOURCES :

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

Honda & Acura Performance Handbook (Performance Handbooks)
Author: Mike Ancas
Order this title from Amazon.com.
June, 1999
Publisher: Motorbooks International
ISBN: 0760306699

Honda/Acura Engine Performance: How to Modify D, B and H Series Honda/Acura Engines for Street and Drag Racing Performance
Author: Mike Kojima
Order this title from Amazon.com.
April 2002
Publisher: HP Books
ISBN: 155788384X

Honda/Acura Performance Handbook: High Performance Modifications for Street and Drag Racing Applications
by the editors of Sport Compact Car Magazine
Order this title from Amazon.com.
November 1999
Publisher: HP Books
ISBN: 1557883246