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The article I referenced was for the older, long airpack. I'm not aware of a rebuild kit for the newer / shorter ones, nor any instructions. I bought a NOS short one and installed it.

I replaced my rebuilt (long) airpack yesterday with the new (short) one. The one I had rebuilt, spilled copious amounts of brake fluid out the air side, so clearly I either did something wrong in my rebuild, or got a faulty part. It's baffling me, because I followed 2 sets of instructions (the...

Having rebuilt my airpack and bled the system twice, I had a firm pedal for a few days and then nothing--all the way to the floor. Also I was hearing a hissing at the firewall (presumably the vent line) that was not present before. So I must have screwed something up in the rebuild. I have no...

Well, now I'm thinking that I must have done something wrong. When I did the rebuild, everything SEEMED straightforward and I didn't have any leftover parts, but now my brake pedal continues to get soft. Bleeding the system firms it up and then it gets soft again. And the air compressor runs a...

http://www.steelsoldiers.com/showthread.php?3229-Deuce-Power-Bleeder-R4x4-Style If money is not a problem (and it sounds like maybe it isn't) you can just buy a new airpack. http://www.memphisequipment.com/PartsDetail.aspx?id=10000259 (Memphis is just one parts dealer, I'm sure others have them)

Ha ha the coop cleaning was easy, predictable, and no surprises! I got the result I expected from the effort put in. Wish I could say the same for the deuce! RE bleeding I would honestly say try it again. The first time I bled my brakes I ended up with a soft pedal. It sat for a few days and...

Update: I got all the correct fittings at AirHydro, and my airpack is reinstalled. BUT when I'm trying to bleed the system, the Master Cylinder is leaking at the cap. I took the copper washer out and sanded it a little but no dice, it is still leaking when I pressurize the system. So I need to...

Went to NAPA today and found a couple of parts towards plumbing in the switch on the air side but still a few pieces short. Would help if I knew what I was looking for instead of just picking up and test-fitting everything I see. But getting there! Edit: the ladies working NAPA on a Saturday...

I was able to get the piston halves apart by cutting back the old rubber cup with a knife and then sticking a small screwdriver in between, carefully, so as not to mar the metal. I seem to have found 2 o-rings that are NOT in the rebuilt kit. The one between the piston halves is beveled to fit...

The online sources for new-old-stock OHT that I can find state that it is a PETROLEUM-based oil, not mineral.

Moving on with this, I've got the nut off the big piston but the halves didn't separate. I guess I need to pry them apart? Also, the TM calls for a "felt ring" but my rebuild kit came with just a strip of felt. Is this correct or is mine torn?

Any comment on the above? (this is the problem with using old threads, they tend to be ignored after a while...)

I have discovered this little bit of corrosion inside my air cylinder, but it seems apparent that it is NOT in the path of the moving piston--too close to the "lid" for that. Would you fill it with JB Weld and sand it down, or just ignore it? It's not really rusty now, just missing some metal...

Could the washer be your spring retainer from the air piston side? Mine is a little different but also much newer. Looks like maybe about the right size, though--just a guess!

Nice-looking stuff inside! Isn't this supposed to be the "air" side? To add something useful to the thread: Getting the "plug" off the fluid end (where the brakelight switch used to be) was the toughest thing I've done so far. Couldn't accomplish anything in a vice. Put a box-end wrench...

Answering my own question: a lot of brake fluid comes out of the air pack when you disconnect the lines, but not much comes out of the lines. Easier to clean up than capture, mostly. Uh oh, mine says do not disassemble!

When I remove the airpack do I need to cap off the brake lines with something or is a plastic baggie with a rubber band enough? I know I will need to bleed the system anyway but my deuce is in the garage right now and I want to minimize the mess.