Just finished my front brake upgrade on my 91 and wanted to post the process. Hopefully, it will help the next guy do this a little faster.
I thought it would be a weekend job, and it would be possible, but I discovered a bunch of issues during the process. Ended up rebuilding the entire brake system!
Step 1: Buy parts.
Powerstop rotors and carbon fiber pads brake kit for a 95 FZJ80. Amazon product ASIN B005FKPR8K $186.43
47781-60100Splash Shield $58.03
47782-60100Splash Shield $58.03
47730-60061 Disc Brake Caliper (Right, Front) $150.55
47750-60061 Disc Brake Caliper (Left) $150.55
CityRacer Brake Booster for '90 to '92 Land Cruiser FJ80 Brake Booster for '90 to '92 Land Cruiser FJ80 - https://www.cityracerllc.com/collections/land-cruiser-80-series/products/brake-booster-for-90-to-92-land-cruiser-fj80. $250.00
13044707 CENTRIC Master Cylinder $59.89
Supplies: Moly Grease x2, tons of paper towels and rags, brake cleaner x4, BEER.
The parts below were purchased later when I realized I had a lot more work to do!
90310-35010 Drive Axle Shaft Seal (Front) $8.04
42183-35010 Rear Cover Gasket $8.99
12157-10010 Gasket Drain Plug $1.34
90311-47001 Drive Axle Shaft Seal (Rear) $10.03
BENDIX PDR0580 Rear Drums x2 $137.58
Wit's End Front Axle Offset Tool 80 Series Inner Axle Seal Offset Driver - https://absolute-wits-end.com/80-series-inner-axle-seal-offset-driver/ $38.83
Dorman Rear Wheel Cylinders x2 Security Check - https://www.carid.com/dorman/rear-drum-brake-wheel-cylinder-mpn-w37690.html. $28.65
Powerstop Rear Drum Pads Security Check - https://www.carid.com/powerstop/autospecialty-rear-drum-brake-shoes-mpn-b549.html $48.26
Dorman Rear Drum Brake Rebuild Kit Amazon.com - https://www.amazon.com/dp/B001PYN4MQ $11.00 (note on this kit, the pins that hold the pads on are not long enough, reuse your old ones)
Toyota Brake Cushion Stops Amazon.com - https://www.amazon.com/dp/B01HSN05UQ $11.00 (I couldn't figure out why my brakes lights wouldn't go off, the original pad broke off)
Wilwood Proportioning Valve Amazon.com - https://www.amazon.com/dp/B011B4UX5U. $47.00
Dorman 090-107 Pipe Plug C.S. Hex M10-1.0 Amazon.com - https://www.amazon.com/dp/B001SG8YOY $12.00 (this is a 5 pack, I have 4 left if you want to PM me) Brake Line Thread Adapter, Male M10 x 1 Bubble, Female M10 x 1 Inverted $31.77 on Ebay
Here is the kit and I thought it would be a quick job...
Step 2. Started teardown. Look how tiny the 91 rotors compare to the 95.
Step 3. Discover First Major Issue. Front axle seal failed.
I realized the axle had a slight groove where the seal ran on the axle.
Did a little begging for help on this forum and the Facebook 80 series group. Came up with this expensive little gem that drives the seal in a further 2mm so it rides on new metal.
80 Series Inner Axle Seal Offset Driver - https://absolute-wits-end.com/80-series-inner-axle-seal-offset-driver/
Step 4. Button up the front hubs. Follow FSM for torque specs and seating procedure. There are also a few good videos on Youtube.
Just tried to post a sixth image and got an error that I can only post five images. That's not very helpful. I will respond to this post and keep going...
I thought it would be a weekend job, and it would be possible, but I discovered a bunch of issues during the process. Ended up rebuilding the entire brake system!
Step 1: Buy parts.
Powerstop rotors and carbon fiber pads brake kit for a 95 FZJ80. Amazon product ASIN B005FKPR8K $186.43
47781-60100Splash Shield $58.03
47782-60100Splash Shield $58.03
47730-60061 Disc Brake Caliper (Right, Front) $150.55
47750-60061 Disc Brake Caliper (Left) $150.55
CityRacer Brake Booster for '90 to '92 Land Cruiser FJ80 Brake Booster for '90 to '92 Land Cruiser FJ80 - https://www.cityracerllc.com/collections/land-cruiser-80-series/products/brake-booster-for-90-to-92-land-cruiser-fj80. $250.00
13044707 CENTRIC Master Cylinder $59.89
Supplies: Moly Grease x2, tons of paper towels and rags, brake cleaner x4, BEER.
The parts below were purchased later when I realized I had a lot more work to do!
90310-35010 Drive Axle Shaft Seal (Front) $8.04
42183-35010 Rear Cover Gasket $8.99
12157-10010 Gasket Drain Plug $1.34
90311-47001 Drive Axle Shaft Seal (Rear) $10.03
BENDIX PDR0580 Rear Drums x2 $137.58
Wit's End Front Axle Offset Tool 80 Series Inner Axle Seal Offset Driver - https://absolute-wits-end.com/80-series-inner-axle-seal-offset-driver/ $38.83
Dorman Rear Wheel Cylinders x2 Security Check - https://www.carid.com/dorman/rear-drum-brake-wheel-cylinder-mpn-w37690.html. $28.65
Powerstop Rear Drum Pads Security Check - https://www.carid.com/powerstop/autospecialty-rear-drum-brake-shoes-mpn-b549.html $48.26
Dorman Rear Drum Brake Rebuild Kit Amazon.com - https://www.amazon.com/dp/B001PYN4MQ $11.00 (note on this kit, the pins that hold the pads on are not long enough, reuse your old ones)
Toyota Brake Cushion Stops Amazon.com - https://www.amazon.com/dp/B01HSN05UQ $11.00 (I couldn't figure out why my brakes lights wouldn't go off, the original pad broke off)
Wilwood Proportioning Valve Amazon.com - https://www.amazon.com/dp/B011B4UX5U. $47.00
Dorman 090-107 Pipe Plug C.S. Hex M10-1.0 Amazon.com - https://www.amazon.com/dp/B001SG8YOY $12.00 (this is a 5 pack, I have 4 left if you want to PM me) Brake Line Thread Adapter, Male M10 x 1 Bubble, Female M10 x 1 Inverted $31.77 on Ebay
Here is the kit and I thought it would be a quick job...
Step 2. Started teardown. Look how tiny the 91 rotors compare to the 95.
Step 3. Discover First Major Issue. Front axle seal failed.
I realized the axle had a slight groove where the seal ran on the axle.
Did a little begging for help on this forum and the Facebook 80 series group. Came up with this expensive little gem that drives the seal in a further 2mm so it rides on new metal.
80 Series Inner Axle Seal Offset Driver - https://absolute-wits-end.com/80-series-inner-axle-seal-offset-driver/
Step 4. Button up the front hubs. Follow FSM for torque specs and seating procedure. There are also a few good videos on Youtube.
Just tried to post a sixth image and got an error that I can only post five images. That's not very helpful. I will respond to this post and keep going...
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