Option 1: A complete '94-'95 Mustang non-ABS brake master cylinder system, including a brake block, came with the SN-95 rear disc brake conversion from MPS Auto Salvage. This could be swapped in and some brake lines would need to be modified, but nothing too difficult.
Option 2: Richard from North Race Cars advises that this is the easiest solution and works great. First unscrew the black plug on the front of the brake block, then remove the plunger and spring. Lastly replace the plug with a combination valve plug PN FMS M-2450-A. This part can also be purchased at your local auto parts store.
To get the front brake system...
To get the front brake system swap started, we removed the front caliper bolts and calipers.
For now we just want to loosen...
For now we just want to loosen the strut bolts, but before doing so we supported the lower A-arm with a pole jack.
The cotter pin was removed...
The cotter pin was removed from the ball joint as well as the castle nut to the ball joint. At this time you will need to support the lower front control arm.
Now you will be able to remove...
Now you will be able to remove the front strut bolts and strut from spindle assembly.
Next, remove the wheel bearing...
Next, remove the wheel bearing dust cap, cotter pin, retainer, nut, and then the outer bearing. Now the front brake rotor can be removed.
Once the stock Fox-body dust...
Once the stock Fox-body dust shield and spindle assembly are removed we can start installing the SN-95 parts.
The SN-95 front spindle bolts...
The SN-95 front spindle bolts right into place as you tighten down the castle nut and replace the cotter pin. But what's the difference between '94-'95 spindles and '96-'04 spindles? All '94-'95 Mustang front spindles are a little different than the '96-'04 Mustang spindles, in that they pull the front wheels and tires inside the front fenders by about 3/8-inch more than the '96-'04 spindles. This offers a little more clearance for wider front wheels and tires especially on lowered cars where wheel lip clearance is a concern.
Now insert the end of the...
Now insert the end of the strut onto the SN-95 spindles and tighten down the two strut bolts.
Place the new SN-95 rotors...
Place the new SN-95 rotors onto the spindle assembly.
After the brake pads and caliper...
After the brake pads and caliper bracket are bolted onto the spindle assembly and rotor, the PBR front caliper can be installed. Note: There's a possibility that Ford changes the spindle and/or caliper tools after a couple years. We had to remove about 1-2 mm of material for caliper clearance around the spindle in a small area. The spindles we are using are '04 GT spindles, and it's possible the calipers may be late '90s calipers. With parts conversions like this, always remember nothing usually just bolts right up. Be prepared and do your homework.
Connect the brake lines from...
Connect the brake lines from the PBR front caliper to the hard lines. Note: The fittings were not compatible between the stock Fox-body hard line and the SN-95 brake hose. We used an Edelman fitting (PN EDE-258430 1/4 x 3/16-inch) to adapt the brake hose to the brake line. We found that this was necessary on the passenger side only. The SN-95 driver side brake hose/fitting is a direct fit onto the Fox-body brake line fitting. Repeat installation for the driver side brakes, then reattach the steering linkage, tighten the castle nut, and install the cotter pin to the spindle.