Brake System and Booster Troubleshooting (1 Viewer)

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The reservoir towards the frt of the vehicle is for the frt brakes, but you never know what a po might have done.

After about 6 pumps it starts to get higher, but it's a hard pedal.
If the pedal pumps up higher means you still have air in the system. From your description it sounds like the issue is in the rear. You can isolate the issue rear or frt by carefully using a pair of vise grips and stopping fluid flow to the rear and then to the frt. This is an unorthodox test and can hurt your soft line if you're not careful. Your going to clamp the rear soft line to stop the fluid flow to the rear and then see if the pedal is better/higher. If the pedal is better then you have air in the rear circuit, if there's no change then the problem is probably in frt or the master. Be sure to carefully adjust the vise grips. You want to stop the flow, not crush the hose. You can do the same to test to the frt. I haven't run rear drums in decades but have read a many threads where folks have poured multiple qts of fluid trying to bleed the FJ40s old antiquated drum brakes. Most folks are successful by adjusting the brake shoes tight to the point the tire wont spin and the shoes are tight against the drums, so the wheel cylinder pistons cant move, then they bleed the wheel cylinders. Leave the tires on. This helps force the air out of the cylinders. Once the air is out of the circuit, they re-adjust the brakes per the FSM.

Your booster is nothing more than a really big vacuum canister, it's there to assist in pedal pressure. If it holds manifold vacuum it should be good. The PO of my May of 1975 40 had a stk disc brake frt axle installed and used the stk 1975 drum brake m/c. I drove it for a couple of summers b4 putting it in storage and the brakes worked perfectly. B4 the internet, I installed an FJ40 disc brake frt axle in my 72 40, I had the same result with the drum m/c and 1/2 my brake and bleeding issues went away. In my expeirence, the drum master has a 1" bore and residual valves, the 1976 and later m/c for frt discs have a 7/8" bore and 1 residual valve for the rear drums. I removed the residual valve and installed a proportioning valve when I went to rear disc's & all my brake and bleeding issues went away.
 
Have you tried gravity bleeding the rear brakes?
I have been using a bottle to catch and prevent air from returning. I have been pumping the brakes and watched to ensure there are no bubbles.
I do the driver rear, pax rear, pax front, and driver front in that order. The tees are on the pax rear axel and driver front axel.
 
Was the master cylinder bench bled when it was installed?
 
Yes you have found the and headed down the rabbit hole 👏👏👏👏.
I think that's what I'll name my truck!
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Braking News!

I got my new City Racer Booster and @cruisermatt Aisin Master Cylinder. The booster arrived on Saturday, So, being that I really wanted to know...I installed the new booster with the old Master Cylinder.

Nope. I mean the pedal feels SO MUCH Better, but it didn't solve the problem. (But now the booster passes all the booster tests...)

Bench bled and installed the new Master Cylinder and bled the whole system today. The pedal feels amazing, I could finally hear the rear brakes waking up. After adjusting them tight, pressing the brake pedal a few times, adjusting them tight again, pressing the brake pedal...etc. (Thanks @POTATO LAUNCHER) They grabbed and stopped the wheel!



Took it out for a road test and it stopped at all the right times. I plan to drive it a bit more tomorrow and then back up on jack stands to dial in the drum adjustment. The best part, if you followed me on "I can't drive 55" is the front hubs were still only warm to the touch after 20 minutes of driving 30-60 MPH!! So, the front brakes aren't dragging either!
 
Your brake system was like a troubleshooting simulator with ALL the bugs activated by the brakes class instructor.
I have no doubt you KNOW your system now.

Thanks for following up.
 
Bad booster? It seems to hold vacuum. Did you step on the pedal? Usually a bad booster will effect how the engine runs. You said you fix the vacuum line and it idled and ran better.

If your not getting brake fluid to the rear brakes, you need to find out why. A kinked line, bad soft line. Air in the rear master cylinder resoiviour or maybe its bad and not pushing fluid. Maybe a bad junction sucking air, but that would probably be leaking too. . When you bleed the rears, does the fluid in the rear resoiviour go down?
If one does find a bad booster in a '78 FJ40 where does one find a replacement? I am being told I'll have to find a re-builder and send mine to them... and wait
 

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