Foxbody brake upgrade

[Habs1965]

I have a 91 mustang gt looking to upgrade to front and rear 5 volt what do you guys recommend anyone done this before

[stangstevers]

Many times... Note: This is off the top of my head

In my opinion the best (and cheapest) way is to get the following:

- SN95 spindles (1994 and 1995 only)
- NEW lower ball joints (1995 year)
- 1995 reman calipers
- Ford Ranger axles (have to research I think you need TWO left or TWO right axles)
- Ford Ranger drums

The above is the cheapest route while still having a good base to work on for future mods. You could do the traditional old school 5 lug using the Lincoln discs up front and whatnot but... meh that's an outdated mod (imo).

This will get you to 5 lug and okay braking... Next level up:

- SN95 axles
- SN95 caliper brackets
- SN95 calipers/discs
- 93 Cobra E-brake cables (or 95 cables, custom bracket and FRPP middle cable and welding the e-brake)
- 93 Cobra booster (or 95 booster with mods to the firewall)
- SN95 master
- Factory proportioning valve bypass/delete (MM has an easy to use kit)
- Proportioning valve

Another level up:

- 2003 GT PBR calipers
- MM flex braided line to connect the calipers

Of course, another level up:
- 2003 Cobra calipers, discs up front
- 2003 Cobra rear discs, anti-moan brackets, caliper brackets (same calipers)
- Probably need a 1 to 1 1/16" MC at this point.

Thing to note, to get the right pedal feel, you need to balance caliper size with MC bore sizes, below are the specs taken from foxstang.com If you get too big of an MC, the pedal will be soft. Too little and it won't have enough to close the clamps.

Caliper sizes:

87-93 Front calipers – single 60mm
94/95 Front calipers- single 66mm
94-98 Cobra PBR Front calipers – dual 38×38mm
99+ Cobra PBR Front calipers – dual 40x40mm
99+ GT PBR Front calipers – dual 44.5×44.5mm (that or 40mm, need to figure this out).
Cobra and 94+ rear calipers are all 38mm

Master Cylinder Bore sizes:

79-86 V8 Mustang – 22.22mm (7/8″)
84-86 SVO/Lincoln – 28.57mm (1 1/8″)
87-93 V8 Mustang – 22.22mm (7/8″)
93 Cobra – 25.54mm (1″)
94+ GT – 23.81mm (15/16″)
94+ Cobra – 26.98mm (1 1/16″)
03 Mach1/Cobra – 25.54mm (1″)

[ZR]

For most, stock booster plus appropriate master cyl gives an easy to modulate brake. If more power assist is preferred, yes SN95 booster swap. Maximum Motorsports sell master cylinder / line kit plus adjustable prop valve kits that bolt directly in place without the hassle of making lines, sweet set up. They also offer a rear disc line kit for SN95 calipers with is equally as nicely done.
Go for at least 99up GT set up on the front, great upgrade over stock, Cobra is that much better again. Five bolt axle and drum combo on the back really does provide decent braking with a front upgrade but of course even GT disc stuff on the rear is preferred.

[Slick_89_Hatch]

I have turbocoupe rear discs converted to 5 lug with 04 GT brakes upfront, stock booster with 93 Cobra master and am VERY happy for just a regular street car.

[stangstevers]

Before going with the Cobra stuff I had the PBR GT calipers and regular 95 calipers in back... it was a very good setup too.

[Quicksilver]

Some years ago ZR converted our Fox to 4 wheel discs. I think we have 2002 Front discs, and SN95 rears. The booster was stock. With Hawk pads and the light weight of the car it would stop on a dime!
Unfortunately the car's been sitting for 4 years. This was the summer we were going to ressurect it, but life got in the way(says he, wistfully)

[Parkway Ford Lincoln SVT]

Also, if you are only wanting to convert to 5-lug only, and not change the brake size / type, you can use Lincoln Mark VII front rotors on your stock brakes, and then a Ford Racing or aftermarket kit with 5-lug axles and drums.

[Das 5.0]

ZR just did a Cobra 4 wheel disc upgrade to my 90 Foxbody and my god what a difference. I wish I had done this sooner but took awhile to gather parts.