Full Brake Overhaul - Lines, Shoes, Cylinders, Master Cylinder

Task Description

Complete brake system overhaul including replacement of all brake lines, shoes, wheel cylinders, and master cylinder. Essential for safe operation and required for roadworthiness.

Parts Required

• Master cylinder
• 4x wheel cylinders
• Brake shoe set (all wheels)
• Brake line kit (or copper/cunifer pipe to make custom)
• Brake fluid (DOT 3 or 4)
• Brake line fittings
• Brake shoe springs and hardware kit
• Copper washers for banjo bolts

Tools Needed

• Brake pipe flaring tool
• Pipe bender
• Pipe cutter
• Brake bleeding kit
• Spring removal/installation tools
• Socket set and wrenches
• Wire brush
• Brake cleaner
• Jack and stands

Procedure

Master Cylinder

1. Drain brake fluid from system
2. Disconnect brake lines from master cylinder
3. Remove master cylinder from firewall/pedal box
4. Bench bleed new master cylinder
5. Install new master cylinder
6. Connect brake lines (don’t fully tighten yet)

Brake Lines

1. Remove all old brake lines
2. Use old lines as templates for new ones
3. Cut and flare new lines to match
4. Install new lines with proper routing and clips
5. Ensure lines are secured and away from heat/moving parts

Wheel Cylinders and Shoes

1. Remove drums from all wheels
2. Photo existing shoe arrangement for reference
3. Remove brake shoes and springs
4. Remove old wheel cylinders
5. Clean backing plates thoroughly
6. Install new wheel cylinders
7. Install new shoes with springs
8. Adjust shoes to slight drum contact
9. Reinstall drums

System Bleeding

1. Fill master cylinder with fresh fluid
2. Bleed system starting from furthest wheel
3. Work systematically to nearest wheel
4. Check pedal feel and travel
5. Top up fluid and test thoroughly

Notes

This is a critical safety system. Take time to do it right. Consider having a professional inspect the work before road use. Keep old parts as reference for ordering replacements in future.

Progress Updates

Task updates will be added here as work progresses