Late C6 brake master swap

Today I finished up a late c6 brake conversion. The c5 master cylinder places the mc seal right over the hole that goes to the ABS system. So under hard braking on the track it erodes the mc seals. It’ll start having the pedal sink to the floor at stoplights. Then you get sudden brake failure at the track. The fix is a brake booster and master from a 09+ c6. The firewall is identical to the c6. The early c6 used the same crappy seal design, but with the zr1, we got a much better master cylinder design.

Here’s the parts list for the conversion 97-00 has a different setup from 01-04, check the tabs

https://docs.google.com/spreadsheets/d/1C_pQ5dWDM3KGUW0dqbfYSsMKJdxLB6NOpp8hZTxSKw8/edit?usp=sharing

The process is a bit of a PITA. The four bolts for the booster are buried deep under the dash. There is also a pin holding the booster to the brake pedal. You’ll need a 15mm on a long wobble extension. Take the seat out to do this. Topside the MC is just two bolts and then you can open the brake lines to the ABS. I left the system sealed until I had the new booster in and was ready to install so it didn’t leak all over.

Booster install, you want to secure the nuts into the socket. I used a bit of teflon tape wrapped around the nut to make it snug. The rest of the lines are pretty easy. I ran them along the windshield cleaner tank. That gives you more clearance around the headers and less heat too. Since the early c5 have a factory proportioning valve, it’s easy to add an adjustable one. I also took the opportunity to replace all the stainless brake lines on my wilwoods. They’re probably 10-15 years old by my best guess.

A long pressure bleed later I have a firm and high pedal again.