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1985 4 cylinder Base Model CJ-7

Gently pressed down the parking brake, and the pedal went to the floor with no resistance!!!

20220522_131650.jpg

Yep, I guess they did not get a good swage press on this end?? The little round end piece slipped right off the end of the cable.

None of the big box stores are going to carry steel cable ferrules. Or, a means to press them on. I went by a local West Marine, thinking they would have something. Back about 20 years ago they carried a lot of cable/ends/tools/and even a press you could use. Not anymore.

Bought this crap at Home Depot:

20220522_154540.jpg

The ferrule are aluminum, probably not up to task. The hand swaging tool is pretty beefy. Decided to try it out.

I crimped on two aluminum ferrules:

20220522_154816.jpg

With both ferrules pressed on, this end would not fit into the bracket on the parking brake pedal assembly, a little too tall. So, I cut a little bit off the top to make it match the original steel end:

20220522_160545.jpg

That lasted for about 2" of push down on the pedal:

20220522_162005.jpg

I had figured the hand swage would not work, but had to try. Oh well. Hopefully NAPA will have some steel ferrules and a hydraulic press fixture to install a new end. If not, there is a wire rope/rigging business near by.

There is some pressure on this end, more so then what the hand tool could cope with. But, when you think about it, not extreme either. At the end of the day, this cable end is pulling against the thin steel bracket on the pedal assembly, which isn't super tough.

If I can't get it repaired locally I will see if Inline Tube will warranty it.

Rain coming next few days, so wrapped this one back up, that's it for now.

20220522_165819.jpg
 
I’ve used all-thread coupling nuts to swags an end on. If you have a welder you can weld the end up too.

Didn’t the same thing happen on the last set of cables from Inline?
 
I’ve used all-thread coupling nuts to swags an end on. If you have a welder you can weld the end up too.

Didn’t the same thing happen on the last set of cables from Inline?
Yes, one of the new cables JeepAddict bought from you for his red Scrambler. I still need to go back and repair/replace that cable.

I'm hoping to either figure out/find a local source to swage on new ends.

NAPA does not have any dies small enough with their hydraulic crimp tool :(
 
How about using one of the 1/4” allthread nuts, cut in half, and then use that bolt cutter swager to crush it on?
 
How about using one of the 1/4” allthread nuts, cut in half, and then use that bolt cutter swager to crush it on?
Cable is 1/8" :shrug:

Something like this would work, maybe, if I could crush it:


5-40 = .125 (1/8"=.125)
L=.438 (original is .4375)
W=.313 (original is .375) (not as wide as original, might not matter)

Being stainless, would be hard to swage with hand tools, can't find a local place with small enough dies for a hydraulic crimp :shrug:

Working load for 1/8 cable 400 pounds (break is 2,000 pounds), both according to the internet.

Not sure what the "pull through" is on a 1/8 swage cable stop??

NAPA has these:


BUT, once I go this route the cable end will no longer be "reusable"??

I emailed In Line Tube, waiting to hear back....................................................
 
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May have repaired the broken cable.

Went by the exhaust shop to see if they had anyway to re-crimp this cable hydraulically.

Not really, but kind of. We put the original steel stop back on the cable, placed the stop inside one of these:


Placed that crimper in the hydraulic press, and re-crimped the stop. Crimped one side, then twisted cable 180 and crimped the exact opposite side.

Might work, kind of redneck, but I can't think of any better way to reswage one of these collars. I think we put 3 tons of pressure on the crimper with the press, that should hold up :shrug::thumbsup:
 
May have repaired the broken cable.

Went by the exhaust shop to see if they had anyway to re-crimp this cable hydraulically.

Not really, but kind of. We put the original steel stop back on the cable, placed the stop inside one of these:


Placed that crimper in the hydraulic press, and re-crimped the stop. Crimped one side, then twisted cable 180 and crimped the exact opposite side.

Might work, kind of redneck, but I can't think of any better way to reswage one of these collars. I think we put 3 tons of pressure on the crimper with the press, that should hold up :shrug::thumbsup:
That should work.
 
How much is a tool that would work for what you would need to get that job done next time ?
 
I already have a press at home, so about $30.00 for the crimper tool. I just never even thought about doing it this way. I'll try it out next week, going out of town tomorrow :thumbsup:
 
If you have a hydraulic press you have the hard part. I’ll bet you could make a 2-piece die out of a couple chunks of steel, a grinder, and a drill…0A2DCC6E-AC98-452E-AD95-CBD750193F8D.jpeg
 
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Back in the saddle, piddled around with this one yesterday.

The "repaired" parking brake cable:

20220526_184713.jpg

A few test pulls, it held, so hooked it up.

The air injection tube clamp I needed. 3/4" ID IIRC:

20220530_131406.jpg

Installed the clamp and the parking brake cable:

20220530_141703.jpg

The parking brake pedal wanted to not lock down, so I had to spray lube the mechanism. Worked it back and forth for about 5 minutes, parking brake is fully operational, and the "Brake" light in the speedometer cluster is working (I went back and installed the floor grommet after I took this picture):

20220530_141718.jpg

The rust visible in the above picture is from the two master cylinders leaking. The leaking brake fluid made the OEM seam sealer peel up, exposing bare sheet metal. Just surface rust, NOT cancer.

Drove through my yard some:

20220530_154042.jpg

And drove around for about an hour, city streets and back roads/highways:

20220530_143601.jpg

Very happy with this one, it is running great!!! I only need to install a new, or try to rebuild the original, clutch master cylinder. It leaks sometimes, most of the time it does not!!

It rained before I could cover the Jeep up OR mess with the clutch master cylinder:

20220530_163106.jpg

I just need some OEM base model wheels and it could be this one!!!!

20220530_180447.jpg

Well, it is an '84, looks like factory hard top/steel doors (no snaps, lower door hinges), being picky LOL!!!! But, some OEM steel wheels would be an upgrade over the aftermarket aluminum wheels IMO.

That's it for now :wave:
 
Back in the saddle, piddled around with this one yesterday.

The "repaired" parking brake cable:

View attachment 102876

A few test pulls, it held, so hooked it up.

The air injection tube clamp I needed. 3/4" ID IIRC:

View attachment 102877

Installed the clamp and the parking brake cable:

View attachment 102878

The parking brake pedal wanted to not lock down, so I had to spray lube the mechanism. Worked it back and forth for about 5 minutes, parking brake is fully operational, and the "Brake" light in the speedometer cluster is working (I went back and installed the floor grommet after I took this picture):

View attachment 102879

The rust visible in the above picture is from the two master cylinders leaking. The leaking brake fluid made the OEM seam sealer peel up, exposing bare sheet metal. Just surface rust, NOT cancer.

Drove through my yard some:

View attachment 102881

And drove around for about an hour, city streets and back roads/highways:

View attachment 102880

Very happy with this one, it is running great!!! I only need to install a new, or try to rebuild the original, clutch master cylinder. It leaks sometimes, most of the time it does not!!

It rained before I could cover the Jeep up OR mess with the clutch master cylinder:

View attachment 102882

I just need some OEM base model wheels and it could be this one!!!!

View attachment 102883

Well, it is an '84, looks like factory hard top/steel doors (no snaps, lower door hinges), being picky LOL!!!! But, some OEM steel wheels would be an upgrade over the aftermarket aluminum wheels IMO.

That's it for now :wave:
I think I have a set of those base wheels...8-)
 
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