Brake Booster

While out driving a couple weeks ago I noticed when I pressed the brake pedal that a loud "hissing" sound began as well as the engine RPM changing quite a bit.  After further diagnosis, it appeared that I had a major vacuum leak coming from the brake booster.  Most likely the 41+ year old rubber diaphragm just deteriorated.  Apparently in 1972 the brake booster changed mid-year.  Jan-Aug 1972 used a 1971 brake booster and the Sept - Dec 1972 (and all the way upto 1978) used the later brake booster.  The holes in the firewall are different and the older (which I have) booster is a 6" smaller diameter.

Original brake booster removed:

 

I was able to slide the brake booster out without having to disassemble the master cylinder

Remanufactured Cardone brake booster (compliments of Amazon.com).  I did need to change the engagement pin on the booster and I'm still in the process of adjusting it to ensure the brakes engage at the proper pedal pressure.  There are stories of the reaction disk (a small rubber spacer in the booster) slippping out, but I did confirm that mine is securely in its place.

 

While I had the accessibility, I swapped out the steering coupler for the rack & pinion steering.  The old hunk of rubber had certainly seen better days & the new one dramatically  improves the handling & responsiveness of the car.

Other useful bits I've found along my travels...