KJA rebuild.

[Fagan123]

Hello all, been a member for a while but this is my first post, well second actually, tried in new members section but had no luck. Restoring a KJA ( SJ413 pickup ) and have hit a problem. Stripped everything from the cab for removal but don't know what to do with the brake master cylinder. Would like to remove it without draining the fluid. Do I remove the four bolts around the brake pedal or is it the two on the master cylinder under the bonnet? Have bought new springs, wings, lights, bushes, 80 x 80 box section etc. for the rebuild but this problem is now holding me up. Sorry for my impatience but would like to push the job forward. Any help would be much appreciated.

[twiss]

To be honest with the cost of brake fluid it might be worth just draining and refilling the system if you are removing the cylinder... it will make a lot less of a mess that trying to take it off when its full of brake fluid! The fluid is very corrosive and will damage paintwork.
You could replace the DOT4 with DOT5.1 which may give marginally better braking performance, but its debatable. Its quite easy to bleed the brakes, VERY easy if you use an pressure bleeder such as a gunson easy bleeder. Otherwise you will have to find a friend willing to press the pedal up and down a few times lol
Just don't put DOT5 in it, as it is completely different (silicone based, not glycol ether) and can lead to moisture in the system.

[Brrok_lands]

To remove the master cylinder, undo the 2 nuts holding it onto the brake servo under the bonnet, you should then be able to move the cylinder assuming you have enough "give" in the brake pipes but do be careful not to distort the brake pipes too much. The danger is that one of the metal brake pipes could kink.

The four nuts you can see inside hold on the servo, once the mater cylinder is removed you should be able to get the servo out if you need to.

[Fagan123]

Thanks for the replies. If I remove the two bolts mentioned and disconnect from the pedal should I be able to pull the master cylinder out or do I have to remove anything else from behind the pedal?
May well decide to renew the brake pipes at some point during the build but for now my heads full of what goes where and don't want to overload the old brain, one thing at a time. Don't want to dismantle more than I need to until I need to. Took plenty of photos and made plenty of notes but will still forget something. Will certainly need advice on a few things before I'm finished.
Will try and upload some pics as I go along.

[1066 Boy]

Welcome mate. Would like to see some pictures of your kja.

[Fagan123]

Thanks for the replies, decided to take Twiss' advice and disconnect pipes from master cylinder leaving cylinder attached to body. Thought I was ready to lift body off then realised I need to disconnect 4wd switch. Does this screw in or is it push fit? The KJA requires major surgery to both body and chassis, will try to post some pics shortly. Some of you will know this KJA as I bought it from club member Jordie. Although it requires quite a bit of work I got it at a great price and delivery was included. Thanks Jordie.

[ScottieJ]

There should be a connection that just unclips around 10-12" from the switch.

If you have removed the master cylinder and it's going to be left off for a long time make sure you store it in a way that there's still fluid in there as you don't want the seals to dry out, I've had old seals end up failing after being removed for a while and left with no fluid in.

Good to hear jordi's Kay jay aay is in good hands! It's got the potential to be a mint Sj

[Fagan123]

Thanks for the advice Scottie, will be sure to leave some fluid in to protect the seals. Currently have the KJA on high trollies so I can move it around the garage. Tomorrow's plan is to support the cab and lower the chassis away. Once this is done I will be able to turn the cab over and see what's to do, I suspect there will be quite a bit of welding required. I know there's welding to do on the chassis, will be able to tell how much tomorrow. New to welding and not very good yet but plenty of practice ahead so hopefully will improve as I go along. Will try to get some pics. up in next few days once the cab is split from the chassis.

[donkeychomp]

Welding on the chassis? Now that surprises me...

Good luck with the build and pics please!