failed cert - after your opinions

[007]

Don't know if this helps but.

I think Changing to larger calipers mean's you require a different size Master cylinder.

I was going to upgrade my jeep with this Teraflex big brake kit.
http://www.teraflex.biz/jk-big-brake-kit.html

When it was first released people had issues with brake pedal hitting the floor under load.

Teraflex then released this larger diameter master break cylinder which fixes the issue.
http://www.teraflex.biz/brake-master-cy ... -bore.html

Or your existing master cylinder is stuffed, air in the lines from the work you have completed or possible the rubber hose by the rotors is old and stretchy.

[jonossiksilvia]

If your peddle is going to the floor I'd say youve still got air in the system. The proportsioning (spelling ) should have a bleed nipple facing the rear bumper, yet to see one which doesnt. I've had troubles with the brakes on that red double cab. Put disks on the rear and ended up having to pressure bleed the system. Brakes are alot better now but are looking at finding a bigger booster.
As for your sway bar when Sam (Jammysammy) got one made for his Surf he bent up a mock up swaybar out of 20mm rod, then took that to Ballemy & East and they copied it. Think it cost him $150.

Only two issues tho, you must have sone a pretty good job there fella

cheers tom yeah pretty happy only failed on 2 things but they prob almost the hardest to sort out lol.

looks like i will replace the master cylinder with a bigger bore model, replace all the rubber hoses as 1 looks like it didnt handle brake test too well, bleed system again (didnt see nipple on rear bias valve so cracked lines instead) then send it off to get a full pressure bleed and fluid change.

cheers for tip on sway bar but will see if prado one will work first ( just need to find some pics of them)

[jonossiksilvia]

Don't know if this helps but.

I think Changing to larger calipers mean's you require a different size Master cylinder.

I was going to upgrade my jeep with this Teraflex big brake kit.
http://www.teraflex.biz/jk-big-brake-kit.html

When it was first released people had issues with brake pedal hitting the floor under load.

Teraflex then released this larger diameter master break cylinder which fixes the issue.
http://www.teraflex.biz/brake-master-cy ... -bore.html

Or your existing master cylinder is stuffed, air in the lines from the work you have completed or possible the rubber hose by the rotors is old and stretchy.

cheers i gonna get a bigger bore master ive decided and 1 hose looks pretty shit so will replace them all

[jonossiksilvia]

Does the pedal always go to the floor or just after he's done the brake test an boiled the brake fluid in your calipers? Does the pedal feel ok when you've bled it an adjusted the shoes?

went to floor after test but now goes to floor everytime. before it did have a lot of travel

[Weemsy]

replaced my master cylinder last night (they dont come with a gasket for between the cylinder & booster but we just made one) quick bleed up and bobs your uncle, better pedal than i can ever remember it having

[jakwoo39]

check the adjustment on rear drums, my old landcruiser past cert first time with the brakes being factory rebuilt ones like yours the only difference was i spaced up proportioning valve on mine
and i cant figure out why u need a sway bar i took the factory one out before cert and it had shit loads of body roll and still went through

[jonossiksilvia]

replaced my master cylinder last night (they dont come with a gasket for between the cylinder & booster but we just made one) quick bleed up and bobs your uncle, better pedal than i can ever remember it having

thats good to know. cheers

[jonossiksilvia]

check the adjustment on rear drums, my old landcruiser past cert first time with the brakes being factory rebuilt ones like yours the only difference was i spaced up proportioning valve on mine
and i cant figure out why u need a sway bar i took the factory one out before cert and it had shit loads of body roll and still went through

yeah i gonna have a bit of a play with the brakes 2moro. although pretty sure the valve is set properly - may even rip it out and got with an aftermarket manual adjustable 1.

yeah was a little annoyed bout the sway bar but ill fit 1 to the front once i find out how the factory prado ones fit to chassis and ill do some quick release pins for it - hell may even put back one back in too.

end of day the cert man wants what he wants

[kiwipete]

Not just cert man wanting sway bars fitted either. The WOF guys are looking too and if there was one fitted from factory, they expect it to be there for the WOF now too.

[HJDOZER]

I have just got cert in my HJ60 for body & suspention lifts and had no sway bars fitted front or rear. Have the ruels changed in a month??

[rokhound]

Slightly different set of rules here. Jono has done a SAS amongst other things, not just a basic suspension lift.

[juz]

yeah i gonna have a bit of a play with the brakes 2moro. although pretty sure the valve is set properly - may even rip it out and got with an aftermarket manual adjustable 1.

I took out the factory load sensing valve and replaced it with a Willwood adjustable one. Just had to get a fitting to adapt my hard lines to the willwood ones and take out the return brake line. Worked a treat and cost about $80 I think.

[jonossiksilvia]

so the rear valve has no bleed valve:


clamped off the rear line. didnt really make a difference to the pedal feel

there isnt any room really 2 run a second booster so cramped:


i did however pull the master out was pretty dirty with a thick sludge in the holding tank so id say thats pretty stuffed.

also pulled off the brake hoses. 1 was leaking under pressure, another 1 was expanding, another was starting to crack so gonna replace all four. quite embarrassed bout the hoses but was hard to tell.

guessing these are the factory prado sway bar mounts?


the bit will possibly be stumped on is how to mount the sway bars on chassis as the chassis is inside the mounting points on the axle:

[Sadam_Husain]

also pulled off the brake hoses. 1 was leaking under pressure, another 1 was expanding, another was starting to crack so gonna replace all four. quite embarrassed bout the hoses but was hard to tell.

sounds like your making some progress and have found some problems right there. As far as the master cylinder bore size goes at a guess it should be displacing enough fluid for the braking system coz I think that model surf has the 4 big piston front calipers the same as the prado ones so nothing should have changed there regardless of which callipers you ended up using and I've already upgraded both my trucks from the smaller piston callipers to the large piston surf ones without any master cylinder displacement problems.

[jonossiksilvia]

yeah the marking on the master is a 1 so i guessing its the 1 inch bore model anyway. yeah your right the surf brakes were 4 pots and so are the prado ones that are on there now.

some progress anyway

[tallsam66]

KZN130W Surf calipers (S13) are different bore size to the Prado (S12) cant remember which is bigger tho ....difference is around 1 m P

[jonossiksilvia]

KZN130W Surf calipers (S13) are different bore size to the Prado (S12) cant remember which is bigger tho ....difference is around 1 m P

awesome cheers mate hopefully prado ones are bigger seen slightly heavier factory. ive just have the prado calipers rebuilt 2 months ago as pistons ceased. wasnt cheep as needed 8 new pistons. after spending couple hundy getting them rebuilt i dont really wanna change them

[Gnarly Dude]

When you are replacing your brake hoses my 2c is to replace them with braided brake hoses. Firmer foot and more durable and most hose stores can make them custom length for you to allow for extra travel up front. Just check they are legal.

[jonossiksilvia]

right so i dropped of the master of at save r brakes to get it rebuilt as its a 1 inch bore model. they also making me up new hoses. hopefully be really by weekend as i dont think they will be working today with the snow.

[jonossiksilvia]

so got the new hoses and master back - now to fit them this weekend

hunt still on for swaybar though