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Red72FJ40
03-07-2011, 09:03 AM
Well, embarked this weekend on what should have been a couple hour job replacing my e-brake cable. After wrenching down there for a few minutes I discovered that the plate that hold the brake shoes had sheared off from the transfer case. The brake had never worked in the three years or so I have owned the FJ40 but must have seized up at some point and broke. After removing the drum and plate, I found broken pieces of the mechanism embedded in years of transfer case sludge and dirt. So I need some advice on:
1) where can I buy some e-brake parts.
2) how to get the sheared off bolts out of the transfer case.
3) any instruction for putting this mess back together,
4) how do I take out the rear seal to replace it.

Thanks!

RicardoJM
03-07-2011, 09:22 AM
You can get new parts from Toyota. I had to replace the pins, clips and few items in my ebrake last summer.

What bolts are sheared off? Can you post up a picture?

Do you have the FSM? The diagram for the parking brake is very useful in assembling everything correctly.

A seal puller will pop that seal right out. The new one can be gently tapped right back in. Is there a groove worn on the shaft where the seal is? If there is, you will need to get a speedi sleeve or else it will still leak with a new seal.

Uncle Ben
03-07-2011, 09:34 AM
The bolts are short and soft. You can probably ease them out with an awl or a small pointed punch and small hammer. You might find it easier to simply remove the speedo housing/rear bearing retainer and clean it up and get the broken bolts out. There is shim or two on the back side of it so take care to put them back in afterwards! I'm sure you can source used parts from the club but as Richardo suggests they are also available from Toyota. Be sure to smear some RTV on the out put shaft splines when reinstalling the rear yoke/e-brake drum or it will seep lube though the gear mesh.

SteveH
03-07-2011, 09:46 AM
x2 on caulking the spline shaft! Not a 'usual' place for caulk, but it will leak at the splines.

Red72FJ40
03-07-2011, 10:38 AM
Ricardo, not at home but they are the bolts that hold the e brake backing plate to the transfer case. I do have an FSM at home so I'll take a look.

Ben, thanks for the input. BTW, looks like the bolts are threaded into the transfer case but I did not look behind it. Are there nut on the other side, or are the bolts threaded into the casting?

Jacket
03-07-2011, 11:30 AM
As I recall, Specter also sells a rebuild kit for the ebrake assembly. Something popped loose with my ebrake last summer and it hasn't worked since then. I don't know what to expect when I dig in there, so a kit might be nice to both fix the problem and refresh any old/worn parts.

Uncle Ben
03-07-2011, 11:45 AM
Ricardo, not at home but they are the bolts that hold the e brake backing plate to the transfer case. I do have an FSM at home so I'll take a look.

Ben, thanks for the input. BTW, looks like the bolts are threaded into the transfer case but I did not look behind it. Are there nut on the other side, or are the bolts threaded into the casting?

It's Kevin and they are threaded into the speedo/bearing retainer that also houses the seal.

subzali
03-07-2011, 12:01 PM
...and the speedo housing in turn bolts to the transfer case.

RicardoJM
03-07-2011, 12:14 PM
It's Kevin and they are threaded into the speedo/bearing retainer that also houses the seal.

...and the speedo housing in turn bolts to the transfer case.

So, if the heads snapped off; you should be able to remove the speedometer housing and have a large amount of the bolt that you can put the "metric #12 vice grip socket" onto and remove the remains.:D

Red72FJ40
03-07-2011, 12:46 PM
Thanks, guys. There is so much gunk build up there that I did not realize there was more than one piece, and luckily, Ricardo, I do have #12 metric vice grips.

PhatFJ
03-07-2011, 07:30 PM
You can use a bolt/stud extractor if there is enough sticking out, if not, drill and remove with a screw extractor. There is a double seal mod you can do on the speedo gear case if you want, here is the link http://forum.ih8mud.com/40-55-series-tech/179274-transfer-case-speedo-double-seal-writeup-how.html
I just did it this weekend and it went really well!! SOR does sell the parts you need but you may be just as well off getting them from Toyota.. Good luck!!
:thumb:

Uncle Ben
03-07-2011, 10:19 PM
So, if the heads snapped off; you should be able to remove the speedometer housing and have a large amount of the bolt that you can put the "metric #12 vice grip socket" onto and remove the remains.:D

They probably sheared so they will most likely be flush with the housing.

Red72FJ40
03-08-2011, 08:51 AM
Thanks, Phat, I'll look into it.

Kevin, yep they sheared off, and that backing plate must have been rubbing against there as it spun so the are now "ground" flat!