Chow717
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great pics... this will come in handy when I tackle mine soon.!!
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Cleaning Up the Air Pack & Rebuild
- Thread starter dabtl
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dabtl
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The first pic shows the cap for the hydraulic piston. This has a hole where formerly the brake light switch was placed. I capped it with a 3/8 fine thread plug and a 3/8 fine thread jam nut. Works great.
The second pic shows the hydraulic cylinder end gasket, the piston, bottom gasket and the spring cup ready to be reinserted.
The third shows the removal of the control valves and the kind of crud I found there. They cleaned up easily with paint thinner.
In the end, it appeared that everything in the second air pack had been replaced new, was still in new condition, other than surface rust, and after cleaning I reassembled it. I did use gaskets and the spring from the repair kit where needed. The main problem appears to be the use of too much gasket sealer and a lousy paper gasket for the air pack cap.
After I get the new square o-rings I think this air pack's problems will be solved. Well not quite. It will take extremely narrow o-rings because of the studs welded to the sides of the air cylinder mean the gasket will have to be exceedingly narrow. I will give McMaster-Carr one more try before making my own paper gaskets.
The second pic shows the hydraulic cylinder end gasket, the piston, bottom gasket and the spring cup ready to be reinserted.
The third shows the removal of the control valves and the kind of crud I found there. They cleaned up easily with paint thinner.
In the end, it appeared that everything in the second air pack had been replaced new, was still in new condition, other than surface rust, and after cleaning I reassembled it. I did use gaskets and the spring from the repair kit where needed. The main problem appears to be the use of too much gasket sealer and a lousy paper gasket for the air pack cap.
After I get the new square o-rings I think this air pack's problems will be solved. Well not quite. It will take extremely narrow o-rings because of the studs welded to the sides of the air cylinder mean the gasket will have to be exceedingly narrow. I will give McMaster-Carr one more try before making my own paper gaskets.
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dabtl
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The first two pics here show the rusty bore of the third air pack's hydraulic cylinder. The spring was very rusty. I will use a wheel cylinder hone to clean it up.
The second two pics show the end cap from the air cylinder with crud from gasket sealer and apparently a defective paper gasket along with the condition of the piston seen from the top. I thought this one has to be junk.
The last two pics show the pleasant surprise of a clean bore in the air cylinder with minimal clean up.
When I remove the four bolts at the bottom of the air cylinder I will get the hydraulic cylinder apart and the true nature of the condition will be finally known. I have hopes for this one also.
The second two pics show the end cap from the air cylinder with crud from gasket sealer and apparently a defective paper gasket along with the condition of the piston seen from the top. I thought this one has to be junk.
The last two pics show the pleasant surprise of a clean bore in the air cylinder with minimal clean up.
When I remove the four bolts at the bottom of the air cylinder I will get the hydraulic cylinder apart and the true nature of the condition will be finally known. I have hopes for this one also.
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dabtl
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I finished the third rebuild today. I got a paper gasket cutter off eBay and paper from O'Reilly's to make the end plate gasket. Took four times but it works well when you learn how.
I have now done three air packs. Easy when you have done it a couple of times.
The only problem with the eBay rebuild kits has been the end plate gasket. But, you can over come that quickly.
I have now done three air packs. Easy when you have done it a couple of times.
The only problem with the eBay rebuild kits has been the end plate gasket. But, you can over come that quickly.
dabtl
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The first two pics show the gasket paper from ACE Hardware and the packaged gasket cutter when first opened.
The third pic show the cutter blades uncovered and adjusted to cut the gasket to the proper size.
The last pic shows the gasket cutter on the gasket paper. I turned it with a 3/8 ratchet. You need to do this on a wood surface for the center of the cutter to bite into to hold the pattern steady.
The third pic show the cutter blades uncovered and adjusted to cut the gasket to the proper size.
The last pic shows the gasket cutter on the gasket paper. I turned it with a 3/8 ratchet. You need to do this on a wood surface for the center of the cutter to bite into to hold the pattern steady.
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FireFighterHill
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Have you thought about rebuilding air packs for a fee? Or possibly a swap out deal?
dabtl
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If I were to charge money for it, I might get prosecuted!
It is very easy. The TM has the steps you follow clearly put forth.
The major issue, in my opinion, is cleaning the parts well. Each that I rebuilt had gummy residue which probably stopped them from functioning. I used paint thinner and rags for most. Extremely fine water proof emery cloth on the rest. An easy fix was to use brake cylinder hones for about $15 each where needed.
Get a rebuild kit and follow the TM with this thread and you should be in business.
It is very easy. The TM has the steps you follow clearly put forth.The major issue, in my opinion, is cleaning the parts well. Each that I rebuilt had gummy residue which probably stopped them from functioning. I used paint thinner and rags for most. Extremely fine water proof emery cloth on the rest. An easy fix was to use brake cylinder hones for about $15 each where needed.
Get a rebuild kit and follow the TM with this thread and you should be in business.
FireFighterHill
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Id rather just pay someone like you who already has all the tools and knowledge to do it right so i dont die when my brakes go out cause I messed up the gasket.
dabtl
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I do not consider that a realistic fear. They are quite easy to fix. I bought the cylinder hones and soft jaws for the vice to do it. The rest is hand tools and the TM. Cut a gasket, or perhaps the new kits have a good gasket, and you are on your way.