well I got a new booster from orally.. I took all the bolts and everything else off the old booster including the nipple part that goes into the master cylinder and the bracket that attaches to the pedal assembly with a pin.. The bracket(fork like part with pin) from the old booster that attaches to the brake pedal that threads onto the booster is actually smaller than the stud on the new booster. now the part seems to be made of copper or brass so it should be easy to enlarge and rethread but I just wanted to know if this was something others ran into or if I got an oddball reman booster with a larger diameter stud on the pedal end? Also on the master cylinder side the nipple part that goes into the master seems to be a lot longer, I can replace it with the one from the old booster. I can post pics if it makes it more clear. I just want to make sure I have the correct part before I drill new holes in the fire wall to mount the larger booster. On a side note If someone has the correct bracket that goes with the larger booster I would be happy to buy it from them. thanks for any info you can share...

I have 2 boosters bought from Black Dragon with the same set up as you mention. I'll have to modify the pedal "U" clamp to fit the larger stud and to fit the brake pedal. Keep us informed with your solution to the modification. Guy

nice glad I'm not the only one...will work on it tomorrow

I got my booster from NAPA and it fit perfectly.

I got my booster from NAPA and it fit perfectly.

Same here. Even the later 1975 style booster had the correct threads.

called napa and the part is about $40 morer than at orilley since I do not have a buisness account there. That $40 may be a small price to pay in order to not mess with re threading the nut...

Worth every penny IMO......NAPA gives a discount to AAA members. I wish I'd bought mine at NAPA.....that's why this site is so valuable.....it can save you time and money.

Well problem solved. Went buy a Zshop here in Marietta and found out that the later boosters came with a few different sized pushrod studs and there are a few different sized end brackets that go on them. When you order one from the parts store or even black dragon it is the luck of the draw. He traded me a larger one for the small one I had and all I had to do is bore out the pin end that attaches to the actual pedal to fit my larger pin in. On a side note if you are putting the larger booster in a early 240 you also need to swap out the nipple that goes into the master cylinder with your old one because the new one is too long and will lock up your brakes. Hope this helps someone else out some day...

I need to go study up. On my '73 when I depress the pedal I hear a hissing sound and the pedal effort is much higher. In some ways I kinda like the increased pedal effort as it seems like I have better control. Will the effort required get even higher if leak gets bigger? It affects idle speed. I assume that its not worth the headache to take appart and rebuild myself.

Are the different sizes you talk about tied to a month of manufacture? Perhaps time to join AAA. I am a member of Good Sam towing. They advertise unlimited towing but its unlimited to the nearest shop so that is not very useful if you are far from home.

I have an '81 zx parts car but it looks like that booster is way too big.

Edited April 7, 201213 yr by wa5ngp