FJ40 disc brake conversions are common here on MUD, so mine is nothing new. But, I am starting this thread in the hopes that it will be helpful to anyone doing their own conversion. I also hope that this thread will help me to stay organized and get advice from others. Thanks for reading, posting up advice, comments, attaboys, & whatever!
My skills: I am a rookie mechanic; tall on enthusiasm and short on experience. The only other thing I bring to the table is an abiding love for this old green ’40. I have a few local Cruiser consultants that I can call on, most notably Toyrod, but generally I’m on my own. My family is usually willing to help, too.
My junk: I have a 1970 FJ40 with the stock drum brakes all the way around, and the old school single-line master cylinder. Overall, the brake system is in poor health. The master cylinder leaks, the drums are noisy and dragging, and I have to pump the brake pedal to get the system to work. I regard the whole thing as borderline unsafe.
Goal: Top-drawer, safe, reliable disc brakes at all four corners. The whole enchilada, as they say.
Approach: Swap in a 1976 FJ40 axle up front. I bought the axle from Igy already, so I am committed. (Don’t go pitching mini truck or 60-series brakes to me now. I am past that decision point!
) I'll install Poser brackets and GM calipers out back. I'm using a non-boosted Corvette master. Summit proportioning valve. Napa and/or junkyard brake lines.
Cost: It looks like this whole deal is gonna cost me right around a grand. Wife says okay, so here we go.
My skills: I am a rookie mechanic; tall on enthusiasm and short on experience. The only other thing I bring to the table is an abiding love for this old green ’40. I have a few local Cruiser consultants that I can call on, most notably Toyrod, but generally I’m on my own. My family is usually willing to help, too.
My junk: I have a 1970 FJ40 with the stock drum brakes all the way around, and the old school single-line master cylinder. Overall, the brake system is in poor health. The master cylinder leaks, the drums are noisy and dragging, and I have to pump the brake pedal to get the system to work. I regard the whole thing as borderline unsafe.
Goal: Top-drawer, safe, reliable disc brakes at all four corners. The whole enchilada, as they say.
Approach: Swap in a 1976 FJ40 axle up front. I bought the axle from Igy already, so I am committed. (Don’t go pitching mini truck or 60-series brakes to me now. I am past that decision point!
) I'll install Poser brackets and GM calipers out back. I'm using a non-boosted Corvette master. Summit proportioning valve. Napa and/or junkyard brake lines.Cost: It looks like this whole deal is gonna cost me right around a grand. Wife says okay, so here we go.
When I did my FJ62 axle a while back, there were shims at each of the 4 positions. Some of the knuckle fasteners are missing, others are loose, so it may be that this thing was at one point partially disassembled and then thrown back together. 
For rubber flex lines, I like the basic black stock-looking lines.
