TB removal and then some!!!

[1991 Corvette ZR-1]

Originally Posted by Roadster

Glad you found it mpiecyk....

Need some opinions....as you can see in Pic #1....the replacement high pressure hose is not exactly the same configuration as the factory hose....as there is a slight bend near the connection to the pump...which the replacement hose does not have.....and the factory hose obviously gives more clearance between the line and the pulley...
Pic #2...shows the distance between the pulley and the tube...and that is with me bending the tube slightly....
Pic #3...is the measurement I get between the pulley and the tube... pulley spins freely....but I'm feeling a little uncomfortable with the clearance and don't want to destroy the tube by bending more... now the AC line looks to be about the same configuration as the factory line with which looks like the correct bends... in Pic #4....

Thoughts.....
Attachment 14971Attachment 14972Attachment 14973Attachment 14974

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Tom, on the high pressure hose, maybe try some type of thread lock. I say that because I have the same fittings on my replacement hose. I torqued it down as far as I felt comfortable doing so. Everything was fine for a few weeks. This Easter Sunday, I lost my power steering and had to get a flat bed home. Today I went out to look everything over and the fitting had backed out enough to let fluid spray out until I was pretty much out of fluid.

I got lucky with a 16mm line wrench that I was able to snake through one of the holes on the pulley to retighten the fitting. Sure beats having to drain coolant to take the whole unit off to tighten one fitting. I got it as tight as I comfortably felt I could without stripping the threads. At the very least keep track of the thread(s) visible once it?s fully torqued down or put a mark on the fitting and on on the pump that line up so if the fitting does move, you can visually verify its backing out.

[Roadster]

Originally Posted by 1991 Corvette ZR-1

Tom, on the high pressure hose, maybe try some type of thread lock. I say that because I have the same fittings on my replacement hose. I torqued it down as far as I felt comfortable doing so. Everything was fine for a few weeks. This Easter Sunday, I lost my power steering and had to get a flat bed home. Today I went out to look everything over and the fitting had backed out enough to let fluid spray out until I was pretty much out of fluid.

I got lucky with a 16mm line wrench that I was able to snake through one of the holes on the pulley to retighten the fitting. Sure beats having to drain coolant to take the whole unit off to tighten one fitting. I got it as tight as I comfortably felt I could without stripping the threads. At the very least keep track of the thread(s) visible once it?s fully torqued down or put a mark on the fitting and on on the pump that line up so if the fitting does move, you can visually verify its backing out.

Thanks for the tips Jamall.....I have another hose being delivered on Thursday....and that will give me the correct orientation when connecting the line....also will use thread locker or equivalent when securing that line.... I'm sure that was not a good feeling when you lost the power steering....glad you are up and running again....

[Roadster]

Another busy day planned for later today....front brake caliper rebuild.... get the belt tensioner squared away...take apart the MBC...and see if the inside components can be cleaned and reused....
Also had been looking for a steering rag joint....just in case....and got delivered today....attached to the intermediate steering shaft....that I purchased...all in great shape...will take mine out for a closer inspection...didn't even unwrap it yet...20210407_001049.jpg

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[Roadster]

Had another busy day today...progress made on the following....
Pic #1...disassembled the MC...and removed 2 of the pistons....
Pic #2...first piston looks decent...have to clean and see what shape the "o" rings are in...
Pic #3...may be hard to see...but it looks like an Allen wrench is needed to remove the second piston...
Pic #4...bias spring piston also looks decent....but will have to clean and make final determination....20210407_132340.jpg20210407_130823.jpg20210407_132418.jpg20210407_195219.jpg

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[Roadster]

Pic #1 & 2...popping the pistons for removal...
Pic #3...all 4 pistons removed.. rubber seals although not torn...will be replaced...
Pics #4 & 5.....inside the bores...not bad...some crud buildup...will be soaked and cleaned...20210407_142936.jpg20210407_142933.jpg20210407_151300.jpg20210407_151336.jpg20210407_151326.jpg

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[Roadster]

Also got the belt tensioner apart...spring seems to be in real good shape...but you can tell the teflon tape has seen better days...we had a difficult time removing the spring...we read the article....but obviously missing something...as in spring removal...
The last pic we heated the tube to bend...and we were successful in bending the pipe....hopefully in the configuration that is needed to be away from the pulley...20210407_121614.jpg20210407_123253.jpg20210407_194102.jpg

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[Roadster]

So I have been having this dilemma with the factory PS high pressure hose...the original and the replacement I bought last month... at the time if I knew that I was going to have this problem....I would have never cut my original hose...although doing that I learned about replacement hoses and from my observation....when they manufactured....again these are JMO's....
I just received another hose today from Craig....and the bends and orientation are exact as the factory hose...although the one Craig sent me has the same part # as the one I purchased last month....there appears to be and I am only assuming that there was a slight manufacturing change over the years ...it will be interesting if Craig remembers how long ago he made the purchase....because IMO...the latest ones out there are not totally correct as they are way to close to the pulley....
Some pics...
Pic #1...the hose that Craig sent me on the left and the original hose on the right....just about totally exact in their orientation....
Pic #2...the replacement hose I purchased last month on the left....and the original hose on the right...you don't even have to hold them together to see that they are not configured the same way...
Pic #3...the original hose on the left and the purchased replacement hose from last month on the right... that we heated to bend the tube...although far from perfect...a way better orientation that would be further away from the pulley if I ended up using this part...
Pic #4 & 5....this is Craig's part...and you can see....according to my reference points from the original setup....there is more room between the pulley and the tube...than there is in Pic #6 with the first replacement hose before heating that tube up yesterday...which is way too close....
My suggestion would be to find an older manufactured hose from awhile ago than the most recent ones...again JMO....20210408_172301.jpg20210331_151156.jpg20210407_194102.jpg20210408_173054.jpg20210408_173040.jpg20210331_175623.jpg

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[HAWAIIZR-1]

Originally Posted by Roadster

So I have been having this dilemma with the factory PS high pressure hose...the original and the replacement I bought last month... at the time if I knew that I was going to have this problem....I would have never cut my original hose...although doing that I learned about replacement hoses and from my observation....when they manufactured....again these are JMO's....

I just received another hose today from Craig....and the bends and orientation are exact as the factory hose...although the one Craig sent me has the same part # as the one I purchased last month....there appears to be and I am only assuming that there was a slight manufacturing change over the years ...it will be interesting if Craig remembers how long ago he made the purchase....because IMO...the latest ones out there are not totally correct as they are way to close to the pulley....

Some pics...

Pic #1...the hose that Craig sent me on the left and the original hose on the right....just about totally exact in their orientation....

Pic #2...the replacement hose I purchased last month on the left....and the original hose on the right...you don't even have to hold them together to see that they are not configured the same way...

Pic #3...the original hose on the left and the purchased replacement hose from last month on the right... that we heated to bend the tube...although far from perfect...a way better orientation that would be further away from the pulley if I ended up using this part...

Pic #4 & 5....this is Craig's part...and you can see....according to my reference points from the original setup....there is more room between the pulley and the tube...than there is in Pic #6 with the first replacement hose before heating that tube up yesterday...which is way too close....

My suggestion would be to find an older manufactured hose from awhile ago than the most recent ones...again JMO....

Hey Tom, Happy to hear it worked out for you. I was worried for a bit. [emoji28] I bought the hoses in 2010. Thanks for the update and I hope your projects keep going well.......and then some. [emoji38]🤙🏼


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[Roadster]

Originally Posted by HAWAIIZR-1

Hey Tom, Happy to hear it worked out for you. I was worried for a bit. [emoji28] I bought the hoses in 2010. Thanks for the update and I hope your projects keep going well.......and then some. [emoji38][emoji1688]


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Thanks Craig....very happy...no worries....here is a little more "and then some"...

So there are times I like to experiment....sometimes it works out....sometimes it doesn't.... this is one of those times where it did...
my front caliper brake pistons have seen better days.. of course with the thousands and thousands of repeated heat cycles when applying the brakes....what would you expect...the brake fluid was just baked on and there was no way I would attempt to do a rebuild without completely cleaning them before install....so I tried brake kleen...I tried soaking in the HD Simple Green solution....although these methods did some good...they were far from the results I was looking for....I imagine that I could have used the dremel...but sometimes me and the dremel can be dangerous at times....lol... I also used WD40 and even a high quality metal polish...but still not the results I was looking to achieve.... that's where the 3M 400 grit fine sandpaper came in....although there are still some stains in the inner bores.. .they are lighter in appearance and the baked on brake fluid around the outside rim is gone...just did this a few minutes ago...and as you will see in the pics...it really worked out well...I even have an extra piston on order...just in case...
Some pics....
Pic #1...2 & 3...you can see the crud buildup from over the years...
Pic #4...5 & 6...what a difference with a few minutes with the sandpaper by hand....
Now they will be ready for the rebuild...with new hoses...and painted calipers...next on the list...20210413_215801.jpg20210413_215326.jpg20210413_215331.jpg20210413_223939.jpg20210413_224217.jpg20210413_224223.jpg

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[Roadster]

Making good progress today....one caliper and bracket now painted... removed inner seals from piston cylinder....did not use any sharp instrument...thus avoiding scaring the wall...used my finger and a toothpick...by the 4th one it came out in a second....lol...also still determined to get the second piston out of the MC....I tried a heavy duty pencil type magnet....it grabbed...but not strong enough to pull it out....wondering if there are different strengths of that type of magnet...it would be great if there is such a tool...it would pull right out..
Any ideas on that???
Thanks....some pics....
Pic #1...first coat on the caliper...
Pic #2...second coat on the caliper and first coat on the bracket...will let dry at least 24 hours before even attempting to rebuild....
Pic #3...your finger and a toothpick work just fine for removal....
Pic #4...all front caliper pistons cleaned and sanded...now ready for the rebuild...
Pic #5...if only I had an extra strong type pencil magnet....this would pull right out....ideas anyone....20210414_143842.jpg20210414_150401.jpg20210414_134807.jpg20210414_124402.jpg20210414_150653.jpg

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