Reconnecting Parking Brake Cable Under Dash: 1968 FJ40

[VA Mountain FJ40]

Slowly reassembling my 68 FJ40 build. New engine/transmission/Tcase installed. Emergency brake underneath blasted and rebuilt. New E brake cable installed at transfer case.

I am absolutely hitting the wall trying to get the E brake replacement cable attached up under the dash, at the end of the arm (46301) that the hand brake lever (46110) moves. The cable end comes through the firewall and the cable terminal eyelet goes vertically between two forks found at the top of the E brake lever arm (46301). A flat head pin (46420C) then goes through the hand brake arm - cable end - hand brake arm sandwich, and is secured by the tiniest of cotter pins (95381-01215) though a hole in the end.

Kind of thing that would be trivial to do on a bench, but up in that cramped space, trying to manipulate the parts into alignment and get them to stay in place so I can pin it, I have failed over a hundred times. Not exaggerating. When I think I finally got it, either the pin falls out or the cable end comes loose from the arm (46301).

Driver and passenger seats are removed. Gas tank is removed. Transmission tunnel hump removed. Working on my side looking up under the dash, working with long handled needle nosed pliers. Just can’t get it back together.

I’m even considering just running a chunky zip tie through the brake lever yoke and cable end, pulling it tight, and calling it done.

Thanks,
Chip
VA Mtn FJ40

 

[VA Mountain FJ40]

Also, can someone confirm which of the two holes on the 463301 lever does the 46420 pin thread through? Two to choose from… the third (larger) hole at the top is where the lever itself mounts under dash. I most regrettably don’t remember which hole in the lever yoke I took it out of.
Chip
VA Mtn FJ40

 

[VA Mountain FJ40]

After another 90 minutes of wrangling, the e brake cable is connected under the dash. I ground the cable eyelet down so it was a little thinner and would more easily fit between the forks at the top of the hand brake lever arm. I used the lower of the two attachment holes. I used a thin metal pin to hold the cable eye in place between the split halves of the lever arm. I know I’m going to hell for this, but I slid a thick zip tie through the lever arm forks with the cable eye in the middle. After verifying that the parts were positioned correctly, I snugged up the tie and the e brake cable is now securely fastened the arm of the ratcheting hand brake up under the dash. Finally. The nut and bolt purist inside me is sad,, but after four days of fighting this, I’m gonna call it done.

 

[VA Mountain FJ40]

Here’s photos of the end result.

 

[Mark Jennings]

Is the cable disconnected at the parking brake drum?

I think on my 68, we installed the cable under the dash before I had the drive train in….and I think we had the lower clevis pin out when we initially assembled.

 

[VA Mountain FJ40]

Is the cable disconnected at the parking brake drum?

I think on my 68, we installed the cable under the dash before I had the drive train in….and I think we had the lower clevis pin out when we initially assembled.

No. The parking brake cable has been connected to the parking brake drum since I rebuilt it a couple of weeks ago.

I really, really did not want to drop the rear driveshaft again and disassemble the parking brake drum once more to undo the E brake cable.

It is possible that the eyelet on my replacement cable was just a touch thicker than the original one. After I took a grinder to it and removed some of the thickness, I had much better luck getting the eyelet to sit deep enough in the brake lever arm gap to thread a fastener through it.

Thank you for sharing your experience and for taking the time to help me.

If I ever have to do this again, I will fasten the parking brake cable under the dash before fitting it to the parking brake drum under the truck.

 

[Mark Jennings]

No. The parking brake cable has been connected to the parking brake drum since I rebuilt it a couple of weeks ago.

I really, really did not want to drop the rear driveshaft again and disassemble the parking brake drum once more to undo the E brake cable.

It is possible that the eyelet on my replacement cable was just a touch thicker than the original one. After I took a grinder to it and removed some of the thickness, I had much better luck getting the eyelet to sit deep enough in the brake lever arm gap to thread a fastener through it.

Thank you for sharing your experience and for taking the time to help me.

If I ever have to do this again, I will fasten the parking brake cable under the dash before fitting it to the parking brake drum under the truck.

I’m thinking that’s your issue…everything needs to be ‘loosely goosey’ to allow assembly. I’m using the same cable that came with the rig in 1968 (or I assume so, I’ve had it since 92 and have never replaced). When we restored it in 2017-2018, just cleaned it up and reinstalled. However, when we restored, running gear was installed after body/dash work.

 

[MDH33]

Just did this on my '69. Attached under dash first then attached to drum and adjusted. It was a pin and cotterpin holding the eyelet. Fit in easy.

 

[VA Mountain FJ40]

Yep, lesson learned: when replacing the park brake cable, install the hand brake cable end before installing the cable in the brake drum underneath. I repeat, If I do this task again, I will connect the cable under the dash first and then connect the cable at the drum second.