Where I left off was three weeks ago and man has it been an interesting three weeks. I have managed to get out in the garage at least one day each weekend (even during my weekend class I took) and fought to finish this project. I was able to get rotors and calipers mounted on both sides and started installing the new master cylinder. And that is pretty much when everything when down the crapper...
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| Drivers Side |
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| Passenger Side |
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| Bench Bleeding the New Master Cylinder |
So I get the master cylinder bled, and mount it to the firewall. I then go to connect the pushrod to the brake pedal and attach the brake switch to the pushrod and pedal as shown in the diagram below...
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| This is What it Looks Like When Things Go Right |
I get everything together and decide to check if it works. I connect the battery and now my brake lights are on all the time! What the hell happened??? So I start scouring the web for ideas and it looks like there might be something wrong with my switch. I then decide to clean the switch, maybe it is stuck always contacting the connection. I get play back in the switch and check it when it is not hooked up. The brake lights are off and they come on when I add pressure to the switch. Well that's good, the switch doesn't seem broken. So I hook the whole assembly back together, reconnect the battery, and the damn lights are still always on! Son of a....
I disassemble the who contraption thinking that there is something wrong with the new pushrod. Keep in mind, every time I install or disassemble this contraption requires me to wedge my fat ass upside down between a seat and huge steering wheel, all while working in an area that my fingers can barely reach with the steering column and all the pedals. It is a real pain and uncomfortable. So I get the new pushrod out and decide to compare it to the old one. There is probably 1/8" more steel at the end of the new pushrod than the old, so I decide to grind some of the end of the new one down a bit. After grinding, refitting, seeing the lights still on, swearing, disassembling, and grinding some more about 3-4 more times, the length is the same size as the old pushrod I pulled out. I install the new pushrod one last time, connect the battery, and not the lights aren't only not on, but now they don't even work at all. You have got to be kidding me!!!! Now I go to the message boards and start begging for help. You have got to be kidding me. After trying a couple more different things (like adding plastic weld to build the tip of the pushrod) and spending 6 hours working on this, I decide to pack it in for the weekend and just order a new switch.
