Front brake flex line/hard line union workaround?

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DFXR

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Contemplating a knuckle job in the near future on my 85 FJ60. Has anybody figured out a workaround for the issue with brake flex line/hard line union on the backing plate? Basically you have to remove one of the lines in order to get the caliper out of the way and the backing plate off the housing, which means a brake bleed at the end of the job. I'm trying to avoid this just to make it a little less of a PITA.

I know there are after-the fact solutions: backing plate eliminator from Marlin, running a long flex line from the axle to the caliper and bypassing the union. But I am trying not to let this job turn into more of a can of worms than it will already be. Plus I already spent $ on SS lines a couple years ago and don't feel like replacing them with longer rubber lines. (If I knew then what I know now...)

A search gave me the after-the-fact answers - anybody out there have an ingenious solution they want to share? Or is a little brake bleed just going to be part of the knuckle job saga?

Many thanks for any help-
DF

PS_wheel_0288.webp
 
I just wiggled mine around to make it work and got the backing plate around the spindle. never had to remove and bleed. but I have OEM lines and not braided
 
yep, its what ive done both times, I hung the caliper up on a frame rail with a ratchet strap to hold it out of the way. you can also put them on 5 gal buckets over turned etc. we do the same thing at work with other vehicles
 
I did 4Runner lines from my axle hard line to the caliper. Much happier. No backing plates left either. Cheap and effective. If you can do a knuckle job you can bleed brakes. I'm sure somebody would buy your SS lines.
 
The best solution is to use a NAPA 38881 brake line to go from the caliper to the housing hard line. Other than that you're just "slightly bending" the hard line out of the way, which will make it fail eventually from work hardening.
 
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I seem to recall someone converting their brackets on the shield to completely unbolt. Then the flex line can flex and the hard line didn't have to.
 
ntsqd said:
I seem to recall someone converting their brackets on the shield to completely unbolt. Then the flex line can flex and the hard line didn't have to.
Click to expand...

Yes, you would have to drill/grind the rivets and replace them with bolts.
 
Indeed, bleeding the brakes is not a bad thing, and is not particularly difficult. But I know I'm not the only one out there who doesn't enjoy it for its own sake, especially alone. This knuckle job will take a long time. I am just looking for ways to keep it manageable.

Thanks for all of the replies, much appreciated.
 
Drill out the welds that hold the bracket to the backing plate. Use bolts with the nut on the inside, tack weld the nuts to the inside of the backing plate. Make sure the bolts do not contact the rotors. This allows easy removal from the outside. The other fix, as has been stated, is to go from the axle hard line directly to the caliper.
 
Stumpalama said:
It is part of the plate and not sold separately.
Click to expand...
I've broken off a brake line in the union, tried getting it out but it was seized good. If I can find a replacement union I'll just cut the old one off and weld the new one on. Otherwise I could buy a new/used backing plate ($$$) or use a longer Napa 38878 flex hose from the axle straight to the caliper bypassing the union on the backplate all together. Finding a 10mm union would be the cheapest alternative though.
 
This was my solution. I have done this for several of the guys on Mud too. This is what Lehiguy said in his post too.


Bleeding the brakes is not a bad thing just a pain in the ass during a field fix

Backing plate2.webp
 
If its broken, you might as well take the opportunity to swap brake lines for one that go direct to the caliper. It is a much more better solution IMHO.:hillbilly:
 
I like the idea of turning the union into a field-removable part. But the longer flex line from axle to caliper is looking better and better.

The NAPA part number that was referenced above may have a typo though - 38884 shows a combination flex/hard line. 38881 looks like it is correct (let me know if I'm wrong). Around $19 a side as of today. Also, SOR sells a backing plate eliminator kit for around $90 that has long stainless flex lines and a shim to make up for the missing plate.
 
DFXR said:
I like the idea of turning the union into a field-removable part. But the longer flex line from axle to caliper is looking better and better.

The NAPA part number that was referenced above may have a typo though - 38884 shows a combination flex/hard line. 38881 looks like it is correct (let me know if I'm wrong). Around $19 a side as of today. Also, SOR sells a backing plate eliminator kit for around $90 that has long stainless flex lines and a shim to make up for the missing plate.
Click to expand...

Sorry about that :oops: I've mixed up that number before. 38881 is the correct part.

I edited my post above.
 
I haven't had any luck with sourcing either Napa 38878 12 3/4" or Napa 38881 16" brake hoses. Napa finds them in their system but none of their stores have any. Can anyone provide the Napa store they purchased through?
 
Check a hose shop or a mom and pop auto parts store. Most can build you a hose.
 
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