thebigredrocker
SILVER Star
Man, what a great accomplishment! I remember the thread on this rig before you bought it. What a find! I have enjoyed reading/seeing your tastefull resurection. Fine work sir.

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Finished rebuilding three out of my four rear wheel cylinders on my 2/71 FJ40. Of course, the fourth and final wheel cylinder piston and adjuster were stuck and would not come out of the cylinder. I tried putting it in a vise and using leverage to break it free, penetrating oil, compressed air, freezing the cylinder and then placing it in hot water, and a combination of the above. Still no success. I then found an online discussion about using grease. The discussion advised that grease guns could generate anywhere from several hundred pounds of pressure to several thousand. Sounded good to me. I went out and bought a package of zirk fittings and screwed them in the brake line and bleeder holes. One would act as a plug and the other would be where the grease would be injected. I then began pumping grease into the cylinder. After several pumps, the piston slowly pushed out of the cylinder. Once out, I removed the rubber cups and spring. (For some reason, the plastic spring seats were missing). I was then able to push the adjuster out with a press. It goes without saying that all the parts need to be thoroughly cleaned in the parts washer and with brake parts cleaner prior to reassembly. I was fully expecting the inside of the cylinder to be pitted and corroded, but that was not the case. Unfortunately, my rebuild kit does not contain the plastic spring seats. Now begins the search for the plastic seats... nothing is ever easy...
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The Napa cylinders are cheap and decent quality. Around $25 each I believe. OEMs are around $75 each. @cruiseroutfit may have Japanese aftermarket too for less than oem.
Thanks. I have a busted up original one floating around. The one I really need is the knob for the transfer case. I have three broken ones that all broke in the same spot. Not inspiring a lot of confidence in that design, especially for the $40 they charge. Need to figure out the thread pitch and make something cool for that one. KABAR knife handle, old hand grenade, top of a femur... something manly and dangerous.
2. The CCOT hose sucks. No pics, because I think it's been documented, but it is really poorly made. Seems like a combination of inferior materials and poor craftsmanship. There's no woven center to the hose, just a solid rubber-like hose that is thicker on one side than the other over the circumference of the hose. Just terrible. I'll keep it as a back-up, but I think my 45-year-old original will work better.
One more shiny photo of everything installed again.
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Another thought, I know Brian (@tonsofun) has been messing with his 3D printer...