Jeep XJ. Manual — part 52
REMOVAL
(1) Release parking brakes.
(2) Raise vehicle.
(3) Remove adjusting nut from tensioner rod at the
equalizer (Fig. 38).
(4) Lower vehicle.
(5) Disengage front cable from the cable lever.
(6) Compress cable retainer with worm drive hose
clamp and remove the cable from the parking brake
lever base.
(7) Disconnect parking brake lamp switch wire
(Fig. 39).
(8) Remove parking brake lever assembly mount-
ing bolts (Fig. 39).
(9) Remove lever assembly.
(10) Remove parking brake lamp switch.
INSTALLATION
(1) Install parking brake lamp switch.
(2) Position lever assembly on floorpan and install
lever mounting bolts.
(3) Tighten lever mounting bolts to 10 to 14 N·m
(7 to 10 ft. lbs.).
(4) Insert front cable through the parking brake
lever base. Insure the cable retainer is seated into
the base.
(5) Attach the front cable to the cable lever (Fig.
39).
(6) Connect parking brake lamp switch wire.
(7) Raise vehicle.
(8) Install adjusting nut to the tensioner rod and
adjust parking brakes.
(9) Lower vehicle.
(10) Verify correct parking brake operation.
DISASSEMBLY AND ASSEMBLY
MASTER CYLINDER RESERVOIR
REMOVAL
(1) Remove reservoir cap and empty fluid into
drain container.
(2) Remove pins that retain reservoir to master
cylinder. Use hammer and pin punch to remove pins
(Fig. 40).
Fig. 38 Parking Brake Equalizer
1 – REAR CABLES
2 – EQUALIZER
3 – FRONT CABLE
4 – TENSIONER ROD
Fig. 39 Parking Brake Lever Assembly
1 – MOUNTING BOLTS
2 – FRONT CABLE LEVER
3 – PARKING BRAKE SWITCH
4 – PARKING BRAKE LEVER
Fig. 40 Reservoir Retaining Pins
1 – PIN PUNCH
2 – RESERVOIR
3 – BODY
4 – ROLL PINS
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BRAKES
XJ
REMOVAL AND INSTALLATION (Continued)
(3) Clamp cylinder body in vise with brass protec-
tive jaws.
(4) Loosen reservoir from grommets with pry tool
(Fig. 41).
(5) Remove reservoir by rocking it to one side and
pulling free of grommets (Fig. 42).
(6) Remove old grommets from cylinder body (Fig.
43).
INSTALLATION
CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubricate new grommets with clean brake fluid
and Install new grommets in cylinder body (Fig. 44).
Use finger pressure to install and seat grommets.
(2) Start reservoir in grommets. Then rock reser-
voir back and forth while pressing downward to seat
it in grommets.
(3) Install pins that retain reservoir to cylinder
body.
(4) Fill and bleed master cylinder on bench before
installation in vehicle.
DISC BRAKE CALIPER
DISASSEMBLY
(1) Remove brake shoes from caliper.
(2) Drain brake fluid out of caliper.
(3) Take a piece of wood and pad it with one-inch
thickness of shop towels. Place this piece in the out-
board shoe side of the caliper in front of the piston.
Fig. 41 Loosening Reservoir
1 – PRY TOOL
2 – RESERVOIR
3 – GROMMET
4 – MASTER CYLINDER BODY
Fig. 42 Reservoir Removal
1 – RESERVOIR
2 – GROMMETS
Fig. 43 Grommet Removal
1 – MASTER CYLINDER BODY
2 – GROMMETS
Fig. 44 Grommet Installation
1 – WORK NEW GROMMETS INTO PLACE USING FINGER
PRESSURE ONLY
XJ
BRAKES
5 - 25
DISASSEMBLY AND ASSEMBLY (Continued)
This will cushion and protect caliper piston during
removal (Fig. 45).
(4) Remove caliper piston with short bursts of
low pressure compressed air. Direct air through fluid
inlet port and ease piston out of bore (Fig. 46).
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston. Use only enough air pressure to
ease the piston out.
WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS MAY RESULT
IN PERSONAL INJURY.
(5) Remove caliper piston dust boot with suitable
pry tool (Fig. 47).
(6) Remove caliper piston seal with wood or plastic
tool (Fig. 48). Do not use metal tools as they will
scratch piston bore.
(7) Remove caliper mounting bolt bushings and
boots (Fig. 49).
ASSEMBLY
CAUTION: Dirt, oil, and solvents can damage cali-
per seals. Insure assembly area is clean and dry.
(1) Lubricate caliper piston bore, new piston seal
and piston with clean brake fluid.
(2) Lubricate caliper bushings and interior of
bushing boots with silicone grease.
(3) Install bushing boots in caliper, then insert
bushing into boot and push bushing into place (Fig.
50).
(4) Install new piston seal into seal groove with
finger (Fig. 51).
(5) Install new dust boot on caliper piston and seat
boot in piston groove (Fig. 52).
(6) Press piston into caliper bore by hand, use a
turn and push motion to work piston into seal (Fig.
53).
(7) Press caliper piston to bottom of bore.
Fig. 45 Padding Caliper Interior
1 – SHOP TOWELS OR CLOTHS
2 – CALIPER
Fig. 46 Caliper Piston Removal
1 – AIR GUN
2 – CALIPER PISTON
3 – PADDING MATERIAL
Fig. 47 Caliper Piston Dust Boot Removal
1 – COLLAPSE BOOT WITH PUNCH OR SCREWDRIVER
2 – PISTON DUST BOOT
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BRAKES
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 48 Piston Seal Removal
1 – REMOVE SEAL WITH WOOD PENCIL OR SIMILAR TOOL
2 – PISTON SEAL
Fig. 49 Mounting Bolt Bushing And Boot
1 – CALIPER SLIDE BUSHING
2 – BOOT
Fig. 50 Bushings And Boots Installation
1 – BUSHING
2 – BOOT
Fig. 51 Piston Seal Installation
1 – SEAL GROOVE
2 – PISTON SEAL
Fig. 52 Dust Boot On Piston
1 – PISTON
2 – DUST BOOT
Fig. 53 Caliper Piston Installation
1 – PISTON
2 – BOOT
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BRAKES
5 - 27
DISASSEMBLY AND ASSEMBLY (Continued)
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