Friend of mine has the same rear brake system, 97 Explorer 500, and he has no trouble with it. I get the feeling it might be the piston that needs cleaning and it's not retracting when you let go of the brake lever. I'd start with that. To adjust the mechanical part use the screw and adjust it so that the foot brake is 1 inch above the floor boards at full application. Use the threaded rod if you run out of adjustment with the screw. To change to a hydraulic foot brake you need a complete caliper, foot operated master cylinder and a fluid reservoir. The mounting holes probably don't match up on the caliper, there are no mounting holes for the master cylinder and fluid reservoir. Hold onto your hat when it comes to cost. Caliper without pistons etc $200, pistons $90 each, piston seals $35, bleeders $ $35 each, etc. Find a way to fix what you have!!! Most people never touch the foot brake. It's just there for emergencies.
2001 Sportsman 500HO
Rear drop rack
Last edited by pjmartin; 11-08-2011 at 03:03 PM.