Front brake rebuild Qs

[johnbill]

Adelaide is currently in project mode. I figured that as long as I am avoiding emissions work , I might as well shape up the front end a little. Having spent some quality time staring at the front axle while wrestling TREs, I decided to rebuild the brake calipers, Now let me quash the hijack that is coming:

-yes, I know that 1995 4Runner calipers offer vastly improved braking while still being a bolt-on, and only require minor fab on the dust shield. I also know that combined with a master out of a T100, this is apparently the slickest system to hit braking since hydraulics. Not gonna do it.
-and yes, I know that it's probably cheaper to buy a junker set of 4Runner calipers and rebuild THEM than it is to rebuild stockers. No, I am not a starving college student. I am a starving Firefighter-EMT, thank you. I also am a rank rookie mechanic and am trying to learn by doing. Time consuming? Yes. But I have no deadline for the truck since I have another DD. Like I said, project mode.

So, my first problem is that one caliper has a stuck piston. The three others pop right out with compressed air, but not so our little friend on the lower inside. Shall I WD-40/PB/Mystery Oil? Is that safe for brake parts? Can I give a little taperoo with a brass or even a rawhide hammer without destroying the sides of the piston?

Second, I have a rebuild kit from Specter that contains boots and wires to go around, as well as similarly-sized square (in x-section) o-rings. I must have missed this in the tear-down: where does the o-ring go?

Third, why paint calipers? Everything else on the bottom half of this 60 shows serious cancer, but not the brake calipers. Why bother?

Thanks in advance!

[MJM]

I have never rebuilt a caliper but have bought rebuilt ones from NAPA for $60. Saves a lot of time and they work great.

[lehiguy]

I had the same issue when I bought my FJ60. I had one buggered piston and bore due to a missing clip that allowed water in there which corroded it. I separated the caliper into it's two halves and used emery cloth to smooth both the piston and the bore. I replaced the clip and drove the past eleven years without any problem whatsoever.

[johnbill]

lehiguy, I'm not gettin ya. What clip?

MJM, I thought about the rebuilds, but I'm trying to hold myself to a philosophy of never learning off of a diagram when I can do it by gettin dirty. Eats up a lot of time, but the lessons are worth it.

...

Like the lesson that next time, I'll be saving time and hassle by buying rebuilts whenever I can.

[lehiguy]

Originally Posted by johnbill

lehiguy, I'm not gettin ya. What clip?

MJM, I thought about the rebuilds, but I'm trying to hold myself to a philosophy of never learning off of a diagram when I can do it by gettin dirty. Eats up a lot of time, but the lessons are worth it.

...

Like the lesson that next time, I'll be saving time and hassle by buying rebuilts whenever I can.

Sorry for my lack of clarity, I was reffering to the clips that hold the rubber boots to the caliper, Each piston has one.

[ardave]

I have an OEM rebuild kit that I've about talked myself out of doing if you have interest...........

Think I'm going for the upgrade afterall

[johnbill]

OK, sorry fellas. Freaked out a little too soon. Judicious and creative usage of compressed air got that last piston out, and I'm seeing that the square o-ring goes inside the bore of the cylinder. Questions still remains about painting tho.

ardave, so long as you gots the parts, you might as well get yosef dirty. This is turning out to be way easier--tho way dirtier--than I thought it was gonna be. I can post pics if you're feelin like you need a little confidence-booster.

[Cruzerman]

I know you have stated that you don't want to spend much money, but the 4runner upgrade is so inexpensive, I don't know why you wouldn't want to do it. You do not need to upgrade the master cylinder. I've used the stock one for years (as well as many others) and see no reason to upgrade the MC.

As for the 4runner calipers, they are cheap. I think I paid like $75 for the pair, loaded. I feel that for that price, why would you want to screw around with the old ones that have issues? For $75 I think getting working calipers and new pads a no-brainer. And you get better stopping as a bonus! But that's just me.

[johnbill]

Cruzerman, I'll readily admit there is no good reason to do what I'm doing. In fact, I was finagling the o-rings out with a custom-modified (read: bent with pliers) dental pick today and had to stop and think: WHY? Far more trouble than it's probably worth. And I'll probably end up putting 4Runner cals in there in six months anyhow. I dunno. Now I know what it looks like on the inside? Right guys? I just wanted to see it for myself is all.

[rchalmers3]

Check out those pistons carefully for gouges and pits, especially the one that was stuck. Even new seals won't last if the piston sealing surface is rough.

If even one of your pistons needs replacing, it'll be time to change calipers.

Paint? What, you can't afford chrome??? I'd leave them bare.

Rick

[Cruzerman]

I sure can understand the "I just want to try and do it" attitude. It can be fun and you learn new things (which always is a good thing). I just tend to play it safe when it comes to brakes. And as it's been pointed out, these things are often pitted or gouged making replacement necessary anyhow.

If your cruiser is like most, there will be many (and I mean many) more opportunities to "try and do it" on other projects. Choose your battles. JMHO.

[IndianDoc]

Originally Posted by Cruzerman

I sure can understand the "I just want to try and do it" attitude. It can be fun and you learn new things (which always is a good thing). I just tend to play it safe when it comes to brakes. And as it's been pointed out, these things are often pitted or gouged making replacement necessary anyhow.

If your cruiser is like most, there will be many (and I mean many) more opportunities to "try and do it" on other projects. Choose your battles. JMHO.

Can I hear a big amen X2 on the many battles. :banana :

[lovetoski]

I rebuilt the calipers on my 80, both front and rear. Worked fine. Tried to do it on my 60, but one piston was stuck too tight. Couldnt get it out for nothing.

I'd also recommend going the 4runner route.