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Old 03-07-2011, 10:03 AM
Red72FJ40 Red72FJ40 is offline
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Default It never as easy as it seems.......

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!
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Old 03-07-2011, 10:22 AM
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RicardoJM RicardoJM is offline
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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.
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Old 03-07-2011, 10:34 AM
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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.
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Old 03-07-2011, 10:46 AM
SteveH SteveH is offline
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x2 on caulking the spline shaft! Not a 'usual' place for caulk, but it will leak at the splines.
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Old 03-07-2011, 11:38 AM
Red72FJ40 Red72FJ40 is offline
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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?
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Old 03-07-2011, 12:30 PM
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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.
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Old 03-07-2011, 12:45 PM
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Quote:
Originally Posted by Red72FJ40 View Post
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.
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Old 03-07-2011, 01:01 PM
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...and the speedo housing in turn bolts to the transfer case.
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Old 03-07-2011, 01:14 PM
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Quote:
Originally Posted by Uncle Ben View Post
It's Kevin and they are threaded into the speedo/bearing retainer that also houses the seal.
Quote:
Originally Posted by subzali View Post
...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.
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Old 03-07-2011, 01:46 PM
Red72FJ40 Red72FJ40 is offline
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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.
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