Excellent post Jason. That was some work changing those very rusted u-joints. Here is a shot of the new u-joints in place.
Once we were done with the u-joints it was on to the brake lines. Jeep didn't put much effort into rust control on the TJ and it shows underneath. The brake lines were so rusted they were ~3 times the original diameter in some spots. It took one evening to remove all the brake lines, working hard to maintain their shape as they would be the template for the new lines.
Although the brake line flaring tool broke on the first night, we picked up a new die, 25' of brake tube, various fittings, and a new flex line to the rear axle. We meticulously bent and flared each line, then carefully worked them back into place. this took an entire night. At the end of that night I tried to loosed the bleed screws at each wheel as this was required to bleed the system. Well despite careful nursing of the rusted screws, I ended up snapping one on the rear wheel cylinder. Great. So guess what another job to do. The next day I replaced both wheel cylinders. Finally with Jonathon sitting in the drivers seat pumping the brakes, I went through ~2L of brake fluid bleeding the system. While doing this I managed to find all of the loose fittings, by following the trails of leaking brake fluid. :-) Then we were done.
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