1990 HDJ81 Caliper Brake Line Craziness (1 Viewer)

[Skippyd]

I feel like I'm going crazy! I have been trying to upgrade the front brakes and wanted to refresh the original soft brake lines.

The first set of lines I got where part number 90947-02a16, and they would not thread on to the hard line fitting. I looked again and noticed these lines are actually for later model years.... So after searching around I thought 90947-02612 and 02613 were the correct lines. However, these will still not thread on.

Both sets of lines seem just a tad too small in diameter to thread on correctly. Is there something I'm missing? It almost like I need an 11mm fitting, but the new lines are 10mm.

The original lines don't have any markings remaining, and look just a little different than the new ones.

 

[Skippyd]

The old line will push all the way to the thread, but the new line gets caught on the flare.

 

[DancesWithMutts]

Hey man, this probably isn't going to help you too much, but when I upgraded the brakes on my 1990 HDJ81 to FZJ calipers, I used the 90947-02A1.

Here was the parts list I got from ONUR for my conversion, it all worked like a charm. I'm not sure what you've got going on with yours though.

Note I was also retrofitting FZJ brakes to the rear of my 81 too.

6 correct:

90947-02A16 (x2): Front calipers
90947-02614: Rear RH Caliper
90947-02615: Rear LH Caliper
90430-10074: x8 high pressure gaskets at caliper.

Then, if you have a lifted truck, I’d go with 96940-34705 x2 for your two frame-to-axle soft lines— gives you 3-4” of extra length for articulation.

So total of 6 lines for non-ABS disc brake truck.

You can get all of these from @NLXTACY/ Wits End.

 

[Skippyd]

The 02A16 seem better than the 02612/13 set, but I still can't get it to engage the threads.

Idk why someone would have switched the fitting to a different size, but I guess I'll take it to the store and see if I can figure out what thread the original lines are. Then I'll go from there.

 

[TomH]

I recently replaced all the rubber brake lines on my Land Cruiser and I had one line with the same problem you are having. It was difficult to unscrew the nut on the hard line when I removed it from the original rubber hose and then I couldn't get it started on the new rubber hose. I concluded that when the hard line was originally tightened it somehow flared the line a little more. I ended up pulling the nut back and lightly filing the flare until it fit in the new rubber hose. It then tightened up with no leaks.