Long Travel Soft Brake Pedal

Update: been driving it for a few weeks. Going to a Cars Coffee 15 miles away rear brakes started tweeting chirping moaning because not enough slack in emergency brake cable. Reduced tension in cable and test drove again but one side still made noise. So I took rear disc brakes apart and found the pads on one side had excessive tightness in caliper bracket. So did the following:

1) Removed caliper bracket and used file belt to grind down where brake pads sit. One ear on one pad needed some grinding too.

2) Added green disc brake grease to caliper pins and on caliper bracket where pads slide. Pins did have some grease, they were not dry, but made sure they were well greased.

3) Verified pads moved freely in both caliper brackets. They should fit firm but slide freely by hand.

4) Used 180 grit sand paper on rear rotors and pads to remove minor glazing caused by dragging brakes. Wiped rotors down with Acetone.

5) Reassembled and activated emergency brake cable many times to adjust rear pads. Then stepped on brake pedal.

6) After emergency brake activated several times and brake pedal depressed / released I could easily turn rear rotors with my hands by the lug nuts with tires off. Before I was not able to turn by hand had to use crow bar or long screw driver in lug nuts. So very noticable difference on rear brakes ability to fully release.

7) No issues at all with front brakes. Front tires move freely no dragging. Those are slider type calipers, not pins, and I did apply brake grease on slider surfaces on initial assembly.

Took for test drive and zero noise now. Cruising around at speed limit normal driving car stops with very little leg effort. Pedal feels solid and inspires confidence. Still more pedal travel then other cars I drive but car starts to slow down without much pedal travel. So even though pedal can travel a bit more then most cars you get used to it and not something I really notice much. Car begins to slow around 1 inch or so pedal travel and very little leg effort. Very good driving experience which was what I was looking for.

Emergency brake does hold car in my sloped driveway. With old rear drums car would roll some.

I think the brakes are now working as best as possible for manual 4 wheel disc. Overall happy with results.

Thnx for the report, - lotta folks leave us hanging.
nice work finishing it off .
Wishing you lotsa miles, lotsa smiles .

Good job.