Well, everything was going smooth yesterday on my '69 T-Bird brake repair until I broke one of the mounting studs for the master cylinder! (One of the 2 studs that mounts the master cylinder to the power booster). This was just before dark last night. I've got about 1/2 " sticking out so I could tighten 2 nuts against each other and try to turn it out of the booster, but I bet it's solid rust....and really not enough to engage full threads on both nuts. Before I do this, though, I'm wondering if the studs are pressed into the booster from the inside. On the non-power brake cars, the studs are threaded into the firewall, but on the booster you have to keep a vacuum, so they may be mounted differently. Anyone got any idea how they are mounted?
Thanks.....that's what I didn't want to hear! lol I wonder if the wall is thick enough to thread and seal with locktight if I were to drill it out and tap it. I don't have much to loose at this point----maybe the core on the power booster.
Any that I have seen are just stamped sheet metal. Any chance of welding a stud to the broken part? Most of those boosters can be separated and re-assembled. It's time consuming, but it may be the best fix in the long run.
I thought about welding onto the stud, but I would be concerned about putting heat on the booster and it's old, brittle diaphragm. Well, buying a re-manufactured booster and master cylinder assembly was an option, and as typical, I went for the cheap route. I really think at this point, I might as well replace the booster, since after all, it's 43 years old and rusty. I could get that re-manufactured master cylinder on there today and the old booster would leak next week! lol
Probably the wisest, but I would have tried the cheap route first, just like you did. Best of luck with it, whatever road you choose.
