The Life & Times of Shasta (86 FJ60 conversion to HJ60)

[TLC Norway]

Hey, any news!? Beer and a sweet sixty, I guess that calls for an update!

 

[ontherxs]

Forgive the intrusion... Happened into this thread somehow. Nice 60 and fantastic diesel swap. Love how you get your kids involved. Very cool build threAd.

Thank for the kind words. Just trying to give a little back to all the education I get here.

Hey, any news!? Beer and a sweet sixty, I guess that calls for an update!

Update is long overdue. I have been so busy with work and family I haven't had anytime really to address the issue of the day. The brake lockup on the rear PS Drum. I finally got some time this past weekend to dig in. The thread where this first started. https://forum.ih8mud.com/threads/brake-lockup.845949/page-2#post-9685308

More below.

 

[ontherxs]

So this past weekend, I finally got some time to pull apart the rear brakes. After reading the FSM and watching this video -> I had the confidence that I could tackle this job.

This will be my first experience with replacing/restoring a brake system.

The PS side was seized up. I attempted to use the two screw driver method through the adjustment hole in the back plate to turn the adjusting arm to "release the pads" I could not get it to turn using that method. So I figured I'd take apart the working DS drum to see if my technique was right. After struggling to get the drum off and some more research, I realized there are two bolt holes in the drum that can be used as means to "push" the drum off by wrenching down service bolts. Here is some pictures of getting the drum off.

Took some time to teach the oldest one how to pull off the wheel.

Seen better days.

Bolts in the extraction port. This is actually the PS, I forgot a picture of the DS.

First issue the bolt used to push off the hub got stripped and wouldn't come back out so we had to cut off the heads

 

[ontherxs]

After wrestling a bit we finally got the drums off.

This is the working side. Nasty Dirty.

Cleaning up before disassembly

Shoes, arms, and springs removed.

On to the stuck PS.

It finally came off.

 

[ontherxs]

On the seized up passenger side as soon as we touched the cylinder it started to leak.

Nice hole in the boot

Removed the rest of the bits and then the cylinder too.

Next time refresh/wire wheel the drums.

Before

Half way

Love to see that logo unburied from all the brake dust and grime.

 

[ontherxs]

All cleaned up. Time for some paint.

First coat. While we wait, spent some time cleaning the rest with all the components now removed.

I'll go back and clean up the hub a bit more later.

Paint job complete.

Inside cleaned (not painted) the surfaces on both seem to be in good shape. Shiny and smooth.

Thats all for now. Time to order some parts. It came up before that maybe it was the soft line which, on inspection was a bit dry rotted, but the inside was not collapsed. Only bummer was in removing the softline, I broke the main hard line running to the front.

Rest of the parts are taking a bath in parts cleaner this week and I'll see what's usable but for the most part going to replace all springs and the cylinders.

For those that made it this far thanks!. Here is the parts list request I sent to @beno. I may end up making that one hard line rather then getting the toy original. This isn't going to be cheap.

90506-20033 SPRING, TENSION(FOR PARKING BRAKE BELL CRANK RETURN) QTY 4
90506-18031 SPRING, TENSION(FOR REAR BRAKE SHOE RETURN) QTY 2

SPRING, TENSION(FOR REAR BRAKE SHOE RETURN)
90506-26011 RH QTY1
90506-26014 LH Qty1

47491-20011 PLUG, HOLE(FOR REAR BRAKE) QTY 2
47447-60010 PIN, SHOE HOLD DOWN SPRING(FOR REAR BRAKE) QTY4
47449-30020 CUP, SHOE HOLD DOWN SPRING(FOR REAR BRAKE) QTY8

WASHER, C(FOR REAR BRAKE)
90213-06013 T=1.2, T=1.2 QTY2
90213-07010 T=1.6, T=1.6 QTY2

96160-00500 RING, E(FOR REAR BRAKE) QTY2
47643-60010 LEVER, AUTOMATIC ADJUST, RH(FOR REAR BRAKE) QTY1
47644-60010 LEVER, AUTOMATIC ADJUST, LH(FOR REAR BRAKE) QTY1

90506-12031 SPRING, TENSION(FOR REAR BRAKE AUTOMATIC ADJUST LEVER) QTY2
47550-60120 CYLINDER ASSY, REAR WHEEL BRAKE(FOR RH, FRONT OR UPPER) QTY1
47550-60120 CYLINDER ASSY, REAR WHEEL BRAKE(FOR LH, FRONT OR UPPER) QTY1
04495-60010 SHOE KIT, REAR BRAKE QTY 1

47323-60031 TUBE, REAR BRAKE, NO.3 QTY1
47325-60100 TUBE, REAR BRAKE, NO.5 QTY1
96940-33805 HOSE, FLEXIBLE(FOR REAR BRAKE TUBE) QTY1

 

[ontherxs]

And we're back. Long weekend of wrenching and the new rear brake system overhaul is done! Big thanks to @beno for getting me the parts. Note to those considering this refresh the hard lines are no longer available, so I ended up going to the parts store and making my own. It was fairly straightforward and not nearly as intimidating as I built it up to be.

Side note: that video I referenced above was good but, the adjuster arms and return springs on an 86 are little different.

Here are some pics. Let the games begin.

And the winner is? @Rice correctly predicted it was a collapsed line. Initially thought it was the flexible line but after removing the hard line that runs up to the engine this damage was discovered. So it was acting a check valve. As to why it was only the DS rear, I suppose it's because the DS is closest lengthwise to the brake master cylinder.

Out with the old

Bending the new to match

Not exact but it works.

 

[ontherxs]

More pics.

Draining the old fluid

Scott, bending lines for me.

New cylinder assembly

Installed

E-brake arm back in

 

[ontherxs]

Last bit.

Reassembly of the shoes.

All in an adjusted

Drums back on.

Beer:30 . BTW this is a fantastic beer when you're sweaty, dirty, and it's hot as a mofo.

Body work and exhaust, you're up.

 

[OGBeno]

Great work. Nice work arounds for those hard lines.

 

[Rice]

Well done, man. Really glad she's rolling.

 

[TLC Norway]

Good job!!

 

[mtweller]

Nice work!

 

[roadstr6]

Hey Tim, Did you have Shasta towed on a rollback from URE back at Christmas when the leaf spring broke? If so that's most likely when the hard line got smashed. Tow truck drivers do this all the time...throw the big tie-down hooks over the axles and cinch them down without looking to see if they are over top of a brake line. Maybe this isn't what happened here but in the future it is something to look out for. I can't tell you how many hard lines I've had to fix or replace on old cars I've done work on for this exact reason. FWIW I have been able to use vice grips tightened in small increments to unsmash lines like this. You end up with a section of ugly squarish-looking line but as long as the fluid is moving you're good to go...at least until you can source a replacement. Shasta is looking good!

 

[ontherxs]

@roadstr6 You know what you are correct. I did have it towed back and that's when it could have occurred. They only place I drove it post suspension fix was to my buddies farm in henderson. I did replace the starter and I guess I could have mashed the line pulling out and putting in the new starter. Its a mystery. This was a fantastic learning experience for me. Enjoyed every agonizing minute of it.

 

[runningdaddy]

This is a fantastic thread! Thankful I ran into your brake issue thread to find this one. You've tackled many of the problems I'm facing right now.
I'll be keeping my eyes on this one!
Happy 4th!

 

[ontherxs]

What weekend Shata had major progress on Shasta. @GLTHFJ60 and I finally found a weekend that we could finish some lingering projects. It only took a year, but it was well worth the wait. So without further adieu, I present rear crossmember and exhaust.

But first, since my big 40 is coming this Friday while at logan's run, I got a little early present. New 33" BFGs AT KO2s for Shasta. Went down as size and got rid of the mud tires and the ride is night a day.

Shout out to my friends at the Oberlin Exxon. The last real service station around.

Now onto the show.

Tailgate off.

This is where we started. Rusted and busted.

 

[ontherxs]

First step hack off the current cross member

Next prep for welding.

 

[ontherxs]

Used the hi-lift to hold the frame apart so the new piece would be snug

Cutting the hole for the trailer receiver

Johnny and his plasma

 

[ontherxs]

Layin down dimes.