Jeep Wrangler TJ. Manual — part 249
(7) Remove caliper mounting bolt bushings and
boots (Fig. 16).
CLEANING
Clean the caliper components with clean brake
fluid or brake clean only. Wipe the caliper and piston
dry with lint free towels or use low pressure com-
pressed air.
CAUTION: Do not use gasoline, kerosene, paint
thinner, or similar solvents. These products may
leave a residue that could damage the piston and
seal.
INSPECTION
The piston is made from a phenolic resin (plastic
material) and should be smooth and clean.
The piston must be replaced if cracked or scored.
Do not attempt to restore a scored piston surface by
sanding or polishing.
CAUTION: If the caliper piston is replaced, install
the same type of piston in the caliper. Never inter-
change phenolic resin and steel caliper pistons.
The pistons, seals, seal grooves, caliper bore and
piston tolerances are different.
The bore can be lightly polished with a brake
hone to remove very minor surface imperfections
(Fig. 17). The caliper should be replaced if the bore is
severely corroded, rusted, scored, or if polishing
would increase bore diameter more than 0.025 mm
(0.001 inch).
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.
Fig. 15 Piston Seal Removal
1 - REMOVE SEAL WITH WOOD PENCIL OR SIMILAR TOOL
2 - PISTON SEAL
Fig. 16 Mounting Bolt Bushing And Boot
1 - CALIPER SLIDE BUSHING
2 - BOOT
Fig. 17 Polishing Piston Bore
1 - SPECIAL HONE
2 - CALIPER
3 - PISTON BORE
TJ
BRAKES - BASE
5 - 13
DISC BRAKE CALIPERS (Continued)
(3) Install bushing boots in caliper, then insert
bushing into boot and push bushing into place (Fig.
18).
(4) Install new piston seal into seal groove with
finger (Fig. 19).
(5) Install new dust boot on caliper piston and seat
boot in piston groove (Fig. 20).
(6) Press piston into caliper bore by hand, use a
turn and push motion to work piston into seal (Fig.
21).
(7) Press caliper piston to bottom of bore.
(8) Seat dust boot in caliper with Installer Tool
C-4842 and Tool Handle C-4171 (Fig. 22).
(9) Replace caliper bleed screw if removed.
Fig. 18 Bushings And Boots Installation
1 - BUSHING
2 - BOOT
Fig. 19 Piston Seal Installation
1 - SEAL GROOVE
2 - PISTON SEAL
Fig. 20 Dust Boot On Piston
1 - PISTON
2 - DUST BOOT
Fig. 21 Caliper Piston Installation
1 - PISTON
2 - BOOT
5 - 14
BRAKES - BASE
TJ
DISC BRAKE CALIPERS (Continued)
INSTALLATION
INSTALLATION - FRONT
(1) Clean brake shoe mounting ledges with wire
brush and apply light coat of Mopar multi-mileage
grease to surfaces (Fig. 23).
(2) Install caliper by position notches at lower end
of brake shoes on bottom mounting ledge. Then
rotate caliper over rotor and seat notches at upper
end of shoes on top mounting ledge (Fig. 24).
(3) Coat
caliper
mounting
bolts
with
silicone
grease. Then install and tighten bolts to 15 N·m (11
ft. lbs.).
CAUTION: If new caliper bolts are being installed,
or if the original reason for repair was a drag/pull
condition, check caliper bolt length before proceed-
ing. Bolts must not have a shank length greater
than 67.6 mm (2.66 in.) (Fig. 25).
Fig. 22 Piston Dust Boot Installation
1 - HANDLE C-4171
2 - INSTALLER C-4842
3 - DUST BOOT
Fig. 23 Caliper Lubrication Points
1 - BUSHINGS
2 - CALIPER MOUNTING BOLTS
3 - MOUNTING LEDGES
Fig. 24 Caliper Installation
1 - TOP LEDGE
2 - BRAKESHOE TAB ON LEDGE OUTER SURFACE
3 - LEDGE SEATED IN BRAKESHOE NOTCH
4 - BOTTOM LEDGE
Fig. 25 Mounting Bolt Dimensions
1 - 67 mm (± 0.6 mm) 2.637 in. (± 0.0236 in.)
2 - 22 mm (0.866 in.) THREAD LENGTH
3 - CALIPER BOLT
TJ
BRAKES - BASE
5 - 15
DISC BRAKE CALIPERS (Continued)
(4) Install brake hose to caliper with new seal
washers and tighten fitting bolt to 31 N·m (23 ft.
lbs.).
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(5) Bleed base brake system. (Refer to 5 - BRAKES
- STANDARD PROCEDURE).
(6) Install wheel and tire assemblies. (Refer to 22 -
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(7) Remove supports and lower vehicle.
(8) Verify firm pedal before moving vehicle.
INSTALLATION - REAR
(1) Install the brake pads if removed.
(2) Lubricate ant-rattle clips for the disc brake
pads (Fig. 26).
(3) Install caliper to the caliper adapter.
(4) Coat the caliper mounting slide pin bolts with
silicone grease. Then install and tighten the bolts to
15 N·m (11 ft. lbs.).
(5) Install the brake hose banjo bolt if removed
(Fig. 27).
(6) Install the brake hose to the caliper with new
seal washers and tighten fitting bolt to 31 N·m (23
ft. lbs.).
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(7) Remove the prop rod from the vehicle.
(8) Bleed the base brake system, (Refer to 5 -
BRAKES - STANDARD PROCEDURE) OR (Refer to
5 - BRAKES - STANDARD PROCEDURE).
(9) Install the wheel and tire assemblies (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(10) Remove the supports and lower the vehicle.
(11) Verify a firm pedal before moving the vehicle.
BRAKE PADS/SHOES
REMOVAL
REMOVAL - FRONT PADS
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove caliper. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- REMOVAL).
(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. 28).
(5) Grasp ends of inboard shoe and tilt shoe out-
ward to release springs from caliper piston (Fig. 29)
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.
Fig. 26 ANTI-RATTLE CLIPS
1 - ROTOR
2 - ANTI-RATTLE CLIPS
Fig. 27 CALIPER INSTALLED
1 - CALIPER MOUNTING BOLTS
2 - CALIPER SLIDES
5 - 16
BRAKES - BASE
TJ
DISC BRAKE CALIPERS (Continued)
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