AutoZone 1963 Mercury Monterey 6.4L 2BL 8cyl | Repair Guides | Brakes | Hydraulic Brake Systems | Brake Booster | AutoZone.com

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    Jeep Wagoneer/Commando/Cherokee 1957-1983 Repair Information

    Brake Booster

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    REMOVAL & INSTALLATION Jeepster/Commando



    See Figure 1

    Click image to see an enlarged view

    Fig. Fig. 1: Cross-sectional view of the power booster used on the Jeepster/Commando models

    1. Remove all dirt from the master cylinder and booster.
    2.  
    3. Disconnect the pushrod from the pedal linkage.
    4.  
    5. Remove the vacuum hose from the check valve.
    6.  
    7. Disconnect the brake light switch wires from the switch.
    8.  
    9. Disconnect the hydraulic lines at the master cylinder.
    10.  
    11. Unbolt the booster from the firewall and remove the booster and master cylinder as a unit.
    12.  


    WARNING
    Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.

    1. Installation is the reverse of removal. Prior to installation, check the pushrod height. The pushrod should protrude 0.980-.0.995 in. above the booster surface. It has a built-in adjusting screw to regulate the protrusion.
    2.  
    3. Bleed the brakes.
    4.  

    1962-69 Wagoneer and J-Series Truck

    Vehicles during these years were equipped with either a Bendix (vehicles with automatic transmission) or Midland-Ross (vehicles with manual transmission) system. The Bendix system gives a low, wide pedal; the Midland system gives a low, wide pedal; the Midland system gives a high pedal to be compatible with the clutch pedal.

    BENDIX SYSTEM

    See Figures 2, 3 and 4

    Click image to see an enlarged view

    Fig. Fig. 2: Diagram on how to fabricate a tool to measure Bendix booster pushrod height



    Click image to see an enlarged view

    Fig. Fig. 3: Component location on the Bendix brake booster 1962-69 Wagoneer and J-series truck models



    Click image to see an enlarged view

    Fig. Fig. 4: Checking Bendix pushrod height with a gauge

    1. Remove all dirt from the master cylinder and booster.
    2.  
    3. Disconnect the pushrod from the pedal arm.
    4.  
    5. Remove the vacuum hose from the check valve.
    6.  
    7. Disconnect the hydraulic lines at the master cylinder.
    8.  
    9. Unbolt the booster from the firewall and remove the booster and master cylinder as a unit.
    10.  
    11. Installation is the reverse of removal. Prior to installation, check the pushrod height. The pushrod should protrude 1.245-1.250 inches above the booster surface. It has a built-in adjusting screw to regulate the protrusion.
    12.  
    13. Bleed the brakes.
    14.  

    MIDLAND-ROSS SYSTEM

    See Figures 5 and 6

    Click image to see an enlarged view

    Fig. Fig. 5: Midland-Ross brake booster used on 1962-69 Wagoneer and J-series truck models



    Click image to see an enlarged view

    Fig. Fig. 6: Measuring Midland-Ross booster pushrod height with a gauge

    1. Disconnect the master cylinder and wheel cylinder hydraulic lines from the slave cylinder.
    2.  
    3. Disconnect the vacuum hose from the check valve.
    4.  
    5. Remove the mounting bracket-to-slave cylinder attaching screws and lift the booster from the truck.
    6.  

    Installation is the reverse of removal. Check pushrod height with the gauge illustrated. Fill and bleed the system.

    1970-86 Models See Figures 7 and 8

    Click image to see an enlarged view

    Fig. Fig. 7: Cross-sectional view of a single diaphragm power booster used on all 1970-77 Wagoneer, Cherokee and J-series truck models and 1978-83 Wagoneer, Cherokee and J-10 models



    Click image to see an enlarged view

    Fig. Fig. 8: Dual diaphragm power brake booster used on all 1978-83 J-series truck models

    1. Disconnect the power unit pushrod at the pedal.
    2.  
    3. Disconnect the vacuum line at the power unit check valve.
    4.  
    5. Unbolt the master cylinder from the power unit and move it out of the way without disconnecting the brake lines. Be careful to avoid kinking the lines!
    6.  
    7. Unbolt and remove the power unit from the firewall.
    8.  
    9. Installation is the reverse of removal. Torque the power unit-to-firewall nuts to 30-35 ft. lb.; the master cylinder-to-booster nuts to 25-30 ft. lb.
    10.  

     
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