Jeep XJ. Manual — part 51
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(5) Bleed base brake system.
(6) Install wheel and tire assemblies.
(7) Remove supports and lower vehicle.
(8) Verify firm pedal before moving vehicle.
FRONT DISC BRAKE SHOES
REMOVAL
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove caliper.
(4) Pressing one end of outboard shoe inward to
disengage shoe lug. Then rotate shoe upward until
retainer spring clears caliper. Press opposite end of
shoe inward to disengage shoe lug and rotate shoe up
and out of caliper (Fig. 31).
(5) Grasp ends of inboard shoe and tilt shoe out-
ward to release springs from caliper piston (Fig. 32)
and remove shoe from caliper.
NOTE: If original brake shoes will be used, keep
them in sets left and right. They are not inter-
changeable.
(6) Secure caliper to nearby suspension part with
wire. Do not allow brake hose to support caliper
weight.
(7) Wipe caliper off with shop rags or towels.
CAUTION: Do not use compressed air, this can
unseat dust boot and force dirt into piston bore.
INSTALLATION
(1) Install inboard shoe in caliper and verify shoe
retaining is fully seated into the piston.
(2) Starting one end of outboard shoe in caliper
and rotating shoe downward into place. Verify shoe
locating lugs and shoe spring are seated.
(3) Install caliper.
(4) Install wheel and tire assembly.
(5) Remove support and lower vehicle.
(6) Pump brake pedal until caliper pistons and
brake shoes are seated.
(7) Top off brake fluid level if necessary.
Fig. 30 Mounting Bolt Dimensions
1 – 67 mm (
6
0.6 mm) 2.637 in. (
6
0.0236 in.)
2 – 22 mm (0.866 in.) THREAD LENGTH
3 – CALIPER BOLT
Fig. 31 Outboard Brake Shoe Removal
1 – OUTBOARD BRAKESHOE
2 – SHOE SPRING
3 – LOCATING LUG
4 – CALIPER
5 – LOCATING LUG
Fig. 32 Inboard Brake Shoe Removal
1 – CALIPER PISTON
2 – SHOE SPRINGS
3 – INBOARD BRAKESHOE
5 - 20
BRAKES
XJ
REMOVAL AND INSTALLATION (Continued)
DISC BRAKE ROTOR
REMOVAL
(1) Remove wheel and tire assemble.
(2) Remove caliper.
(3) Remove retainers securing rotor to hub studs
(Fig. 33).
(4) Remove rotor from hub.
(5) If rotor shield requires service, remove front
hub and bearing assembly.
INSTALLATION
(1) If new rotor is being installed, remove protec-
tive coating from rotor surfaces with carburetor
cleaner.
(2) Install rotor on hub.
(3) Install caliper.
(4) Install wheel and tire assembly.
DRUM BRAKE SHOES
REMOVAL
(1) Raise vehicle and remove rear wheels.
(2) Remove
and
discard
spring
nuts
securing
drums to wheel studs.
(3) Remove brake drums. If drums prove difficult
to remove, retract brake shoes. Remove access plug
at the rear of backing plate and back off adjuster
screw with brake tool and screwdriver.
(4) Remove U-clip and washer securing adjuster
cable to parking brake lever (Fig. 34).
(5) Remove primary and secondary return springs
from anchor pin with brake spring pliers.
(6) Remove hold-down springs, retainers and pins
with standard retaining spring tool.
(7) Install spring clamps on wheel cylinders to
hold pistons in place.
(8) Remove adjuster lever, adjuster screw and
spring.
(9) Remove adjuster cable and cable guide.
(10) Remove brake shoes and parking brake strut.
(11) Disconnect cable from parking brake lever and
remove lever.
INSTALLATION
(1) Clean support plate with brake cleaner.
(2) If new drums are being installed, remove pro-
tective coating with carburetor cleaner followed by
final rinse with brake cleaner.
(3) Clean and lubricate anchor pin with light coat
of Mopar multi-mileage grease.
(4) Apply Mopar multi-mileage grease to brake
shoe contact surfaces of support plate (Fig. 35).
(5) Lubricate adjuster screw threads and pivot
with spray lube.
(6) Attach parking brake lever to secondary brake
shoe. Use new washer and U-clip to secure lever.
(7) Remove wheel cylinder clamps.
(8) Attach parking brake cable to lever.
(9) Install brake shoes on support plate. Secure
shoes with new hold-down springs, pins and retain-
ers.
(10) Install parking brake strut and spring.
(11) Install guide plate and adjuster cable on
anchor pin.
(12) Install primary and secondary return springs.
(13) Install adjuster cable guide on secondary
shoe.
(14) Lubricate and assemble adjuster screw.
(15) Install adjuster screw, spring and lever and
connect to adjuster cable.
(16) Adjust shoes to drum.
(17) Install wheel/tire assemblies and lower vehi-
cle.
(18) Verify firm brake pedal before moving vehicle.
WHEEL CYLINDER
REMOVAL
(1) Remove wheel and tire assembly.
(2) Remove brake drum.
(3) Disconnect wheel cylinder brake line.
(4) Remove brake shoe return springs and move
shoes out of engagement with cylinder push rods.
(5) Remove cylinder attaching bolts and remove
cylinder from support plate.
Fig. 33 Rotor & Hub
1 – ROTOR
2 – RETAINER
3 – BEARING NUT
4 – NUT LOCK
5 – COTTER PIN
6 – WASHER
XJ
BRAKES
5 - 21
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Apply bead of silicone sealer around cylinder
mounting surface of support plate.
(2) Install cylinder mounting bolts and tighten to
20 N·m (15 ft. lbs.).
(3) Connect brake line to cylinder.
(4) Install brake shoe return spring.
(5) Install brake drum.
(6) Install wheel and tire assembly.
(7) Bleed base brake system.
BRAKE SUPPORT PLATE
REMOVAL
(1) Remove wheel and tire assembly and brake
drum.
(2) Remove brake shoe assembly.
(3) Remove parking brake cable from parking
brake lever.
(4) Compress parking brake cable retainer tabs.
Then push retainer and cable through and out of
support plate.
Fig. 34 Drum Brake Components—Typical
1 – ADJUSTER LEVER
2 – ADJUSTER CABLE
3 – HOLDDOWN SPRING AND RETAINERS
4 – ADJUSTER LEVER SPRING
5 – TRAILING SHOE
6 – CYLINDER-TO-SUPPORT SEAL
7 – HOLDDOWN PINS
8 – ACCESS PLUGS
9 – SUPPORT PLATE
10 – CABLE HOLE PLUG
11 – PARK BRAKE STRUT AND SPRING
12 – ADJUSTER SCREW ASSEMBLY
13 – HOLDDOWN SPRING AND RETAINERS
14 – LEADING SHOE
15 – CABLE GUIDE
16 – SHOE RETURN SPRINGS
17 – SHOE GUIDE PLATE
18 – PIN
19 – SHOE SPRING
20 – PARK BRAKE LEVER
Fig. 35 Shoe Contact Surfaces
1 – ANCHOR PIN
2 – SUPPORT PLATE
3 – SHOE CONTACT SURFACES
5 - 22
BRAKES
XJ
REMOVAL AND INSTALLATION (Continued)
(5) Disconnect brake line at wheel cylinder.
(6) Remove wheel cylinder from support plate.
(7) Remove axle shaft, refer to Group 3 for proce-
dures.
(8) Remove bolts attaching support plate to axle
and remove support plate.
INSTALLATION
(1) Apply bead of silicone sealer around axle
mounting surface of support plate.
(2) Install support plate on axle flange. Tighten
attaching bolts to 115 N·m (85 ft. lbs.).
(3) Apply bead of silicone sealer around wheel cyl-
inder mounting surface and install wheel cylinder.
(4) Install brake line in wheel cylinder.
(5) Install parking brake cable in support plate.
(6) Install axle shaft, refer to Group 3 for proce-
dure.
(7) Connect parking brake cable to lever on sec-
ondary shoe and install brake shoes on support plate.
(8) Adjust brake shoes to drum with brake gauge.
(9) Install brake drum and wheel and tire assem-
bly.
(10) Bleed brake system.
REAR PARKING BRAKE CABLES
REMOVAL
(1) Raise vehicle and loosen equalizer nuts until
rear cables are slack.
(2) Disengage cables from equalizer and compress
cable retainers with a worm drive hose clamp.
(3) Remove cables from the cable bracket (Fig. 36).
(4) Remove rear wheel and brake drums.
(5) Remove secondary brake shoe and disconnect
cable from lever on brake shoe.
(6) Compress cables retainer with worm drive hose
clamp (Fig. 37) and remove cables from backing
plates.
INSTALLATION
(1) Install new cables in backing plates. Be sure
cable retainer is seated.
(2) Attach cable to lever on brake shoe and install
brake shoe on backing plate.
(3) Adjust brake shoes to drum with brake gauge.
(4) Install brake drums and wheels.
(5) Install cables into the cable bracket and insure
retainers are seated in the bracket.
(6) Engage the cable ends into the equalizer and
install equalizer nut.
(7) Adjust parking brakes.
PARKING BRAKE LEVER
The center console must be removed to service the
parking brake lever. Refer to Group 23 Interior Com-
ponents for service procedures.
Fig. 36 Parking Brake Cables
1 – REAR CABLES
2 – EQUALIZER
3 – FRONT CABLE
4 – TENSIONER ROD
Fig. 37 Cable Retainer
1 – CABLE RETAINER
2 – REAR CABLE
3 – WORM DRIVE HOSE CLAMP
XJ
BRAKES
5 - 23
REMOVAL AND INSTALLATION (Continued)
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