Rigger's disc brake conversion

[Rigger]

I have both the front and rear circuits almost finished. The tombstones need to be welded on, and I don't own a welder, so I am stymied. Brew8 is coming to the rescue next week.

Here is a pic of the front. The zip ties are temporary!

 

[Rigger]

I ran the rear circuit down the passenger side frame rail. Here in this pic is where the hard line ends and the hose to the rear axle begins. That little angle bracket was stock. I pulled it off, enlarged the hole to fit the new hose, and re-installed it. The clip is not yet installed in this picture.

 

[Blue77FJ40]

Rigger, it looks like you are running the rear circuit brakeline from the prop valve over the booster, putting it higher than the master cylinder. I believe you don't want any lines higher than the mc. Someone chime in here if I"m wrong.

I'd like to see how you did your rear caliper lines, as I'm doing my rdb now.

Thanks, Dan

 

[pappy]

Rigger, it looks like you are running the rear circuit brakeline from the prop valve over the booster, putting it higher than the master cylinder. I believe you don't want any lines higher than the mc. Someone chime in here if I"m wrong.

Not a problem. Toyota has been known to do that from the factory. What you might be thinking of is the placement of the bleed valve which should be placed high instead of low when you mount the caliper.

 

[pappy]

I'd like to see how you did your rear caliper lines, as I'm doing my rdb now.

Mine.

 

[Rigger]

I'll get a picture up as soon as I get the tombstones welded on. My calipers sit up a bit higher, and my soft lines route above, not below, the leaf spring.

 

[Cruiserdrew]

Pappy-How are you ever going to get those brake lines to live in in the rocks? Looks like they are waiting to be scraped off!

 

[pappy]

That is why I left the lower spring mount on the axle.

 

[Rigger]

Rear axle: This pic shows how the tee sits on the axle. The tombstone is being held in place by hand. The hose off of the tombstone goes to the passenger side caliper. The hose (barely visible) from the tee goes to the frame.

 

[Rigger]

In this view, you can see how I have the caliper mounted kinda up high, allowing the brake hose off of the caliper to sit above the leaf spring.

 

[Rigger]

One other thing I got done today was to fill and bleed the clutch master cylinder and slave cylinder kit.

I noticed that the lever that the slave cylinder push rod pushes on has a gasket of sorts where it passes into the clutch housing. The gasket is a bit of a mess, frankly. There is so much dirt and gumpta in there that I can't clearly see what's happening. Does anyone have a good, clean pic of that?

 

[Rigger]

More progress.

Got the tombstones welded on to the back axle.

All brakelines are done.

Next up, bench bleed the master, then fill the system with fluid.

 

[Rigger]

A little more progress: I filled both pumpkin heads and the radiator. This thing doesn't have an overflow bottle, so I guess I have to wait to complete this until I can run the truck.

I got a vacuum hose plug and plugged off the hose that goes to that carb diaphragm that was removed to make room for the new master cylinder.

Got a few miscellaneous nuts and bolts. I still need a few brake line anchors. Gonna make another run to the hardware store tonight.

I had a center arm rebuild kit lying around, so I tried to get that done yesterday. Ran into a snag with that, so I'm scratching my head on that one.

Tonight or tomorrow I am going to try to get this brake system filled with fluid. I am going to have to have some helpers.

 

[Rigger]

More pics. That master reservoir is very close to the air cleaner! I had to "clearance" it a bit! First pic is my redneck brake line holder. An L bracket from the hardware store and a brake clamp salvaged off of a Toyota truck!

 

[Rigger]

I have a set of shocks waiting at Napa. Gotta get them on tomorrow. I also ordered a new front bumper (JTO) and a set of mirrors (CCOT).

 

[Poser]

This thing doesn't have an overflow bottle, so I guess

Looking good bud!

On the overflow bottle...find the bottle and bracket from a 60/62 series. I put them in early trucks and they work well.

 

[TRoss]

Good progress Rigger!! Nice work!

 

[Rigger]

Thanks, Poser. Sounds like I need the following cooling system parts:

16480-90A00 - Reserve Tank
16405-90A03 - Cap Sub-Assembly
16611-61020 - Tank Bracket

(There was some discussion about the bracket being unavailable and this part number was mentioned: 85361-30070)

They are referenced and pictured in this thread, post #8 and post #56.

Coolant overflow bottle (FAQ)

I stuck this in C-Dan's "Gone to Lake Powell" thread. We'll see what shakes out when he returns.

 

[Poser]

Thanks, Poser. Sounds like I need the following cooling system parts:

16480-90A00 - Reserve Tank
16405-90A03 - Cap Sub-Assembly
16611-61020 - Tank Bracket

(There was some discussion about the bracket being unavailable and this part number was mentioned: 85361-30070)

They are referenced and pictured in this thread, post #8 and post #56.

Coolant overflow bottle (FAQ)

I stuck this in C-Dan's "Gone to Lake Powell" thread. We'll see what shakes out when he returns.

All the parts are available. Pablo gets excited if something does not fall into his lap on the first try.


New is not cheap. You could probably find those three pieces used as well if you post up or hit a wrecking yard your way. 60/62 will both work.

 

[Rigger]

New is not cheap. You could probably find those three pieces used as well if you post up or hit a wrecking yard your way. 60/62 will both work.

I checked one yard this afternoon. No Cruisers. I wandered around in there for a while looking for something close off of another rig. No joy. I had a rusted-out FJ62 a while ago, but I never thought to pull that part before I sold it off. I know where there a couple of 60's, but I don't think the bottle is in place on either of them. The bracket is probably there, though.

On to the brakes, I have the master cylinder bled and ready, and I need to bleed the lines next. I am hoping to get to it tomorrow. Problem is, I have also been gearing up for a family camp trip, so been quite busy.