I removed my front calipers due to a front diff swap I'm doing. When I removed them, I notice the fluid was brown in color and there were plenty of contaminants in the caliper bores once I got them apart. The bores themselves look pretty good with just a tiny bit of pitting. I think I can clean them up and not have any issues.

But I'm wondering now that I see the condition of the fluid, do I need to do a full restoration of the brake system? Do I need to replace/rebuild the master cylinder? Do I need to replace all the brakes lines or can I flush them out? If I was to replace the brake lines, does anyone have an suggestions where to buy pre-formed to factory specs lines? I have checked out inlinetube.com. They any good?

I haven't pulled the rear brakes off yet to see what kind of shape they are in, but I expect them to be in equal condition. If they need rebuilt, that won't be an issue either. I'm not interested in the disc swap because I don't want to hassle with fabricating brackets for brake lines or figuring out how to make the parking brake cables/connections work. If it was truly "plug and play", I'd consider it. Convince me otherwise, lol.

I like to do things right and not cut corners at the same time keeping as much of the original parts as I can. Rebuilding calipers is easy so I see zero reason to order a reman caliper as long as the caliper housing itself is serviceable.

I'll replace brake lines, but only if I can't flush out the existing lines to make clean.

 

Hard to answer without seeing the stuff but for what it's worth:
1 I gave up rebuilding calipers decades ago. If the bores are pitted they are shot. If you try honing them they will likely end up oversize or tapered. Seals and pits do not get along.

2) if it's like pretty much every other xj all the underbody metal lines need to be replaced. Use the copper /nickel stuff. It's really no big deal to make your own .
these are the brakes we are talking about .. .

 

I'll see if I can get a couple pics and post them up tonight. They are hard to see.

I have heard that a minute amount of pitting won't hurt since the piston rides on the seal but I will consider just replacing them.

Thanks. I fairly confident in doing most things but not sure about bending tubing and flaring. Along with drywall finishing and laying carpet, lol.

 

In addition to not rusting, the copper nickel line is a lot easier to bend and flare.

 

Here is a pic of the pitting in the bore.

 

Inline tube brake lines are top notch. Heavy duty stainless steel and they’re a perfect fit. I was impressed with the company, the lines and the customer service. The company sells thru eBay 20-30 dollars cheaper. Why? Idk

 

I used Inline tube for my two FSJ Wagoneers

 

Rebuilt calipers and a fluid flush done by you before going nuts here.

 

Yeah, I am going to inspect the brake lines. This is a Texas vehicle without rust so I doubt the lines are bad. I just want to be able to flush out any contaminants present in the lines.

As far as rebuilt calipers, I suppose you are right, just buy them. I do enjoy rebuilding stuff though. I like the process of disassembly, inspection, cleaning, painting, re-assembly, adjusting. Plus I keep original parts with the vehicle. But if rebuilding an assembly whether it be a caliper or an alternator nets me a sub-standard part compared to buying a reman unit, then I will go the reman route.

It's been a few years since I did any substantial restoration work on a vehicle( did a lot back in the 70's, then a squarebody Chevy in the 2000's, then a Miata in 2010) but nothing since and it appears the landscape may have changed some. Being an old formerly ASE master mechanic, I still have some ingrained ideas, lol. Thanks cruiser.

 

The lines are likely just fine given your description.
I always upgrade the hoses though. Braided steel.
As for bleeding/flushing, I suck all of the fluid out of the master with an old turkey baster, fill with fresh fluid, then bleed the system til clear fluid comes out.
Ever see the one man brake bleeder from Hobo Freight? Uses compressed air. I love it!!

 

This one?

 

Yep. It must work well. My neighbors keep borrowing it!!!

 

I'll pick one up at lunch! Looks way better than my hose stuck in a jar!

 

You'll love it.

 

I tried the bleeder out tonight on my wife's car. She had a stuck caliber and I attempted to replace the hose(another story). It didn't work. I followed the directions and I started to get a slight draw but it would never really get the fluid moving.

I ended up sticking the hose in the bottom of the old fluid jar and just pumped the brakes to bleed it.

I'm open to any ideas why it didn't work for me.