Jeep CJ/Scrambler 1971-1986 Repair Guide

Caliper

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6 and 7



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Fig. Fig. 1: Disc brake assembly as used on 1982-86 models



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Fig. Fig. 2: Removing the caliper piston with compressed air



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Fig. Fig. 3: Removing the piston dust seal



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Fig. Fig. 4: Removing the O-ring



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Fig. Fig. 5: Installing the metal retainer (8) into the piston groove (9)



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Fig. Fig. 6: Install the dust seal on the piston by hand



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Fig. Fig. 7: Caliper piston installation

1977-1981 Models

CAUTION
Brake shoes contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  1. Remove 2 / 3 of the brake fluid from the front reservoir.
  2.  
  3. Raise the vehicle so that the wheel to be worked on is off the ground. Support the vehicle with jackstands.
  4.  
  5. Remove the front wheels.
  6.  
  7. Place a C-clamp on the caliper so that the solid end contacts the back of the caliper and the screw end contacts the metal part of the outboard brake pad.
  8.  
  9. Tighten the clamp until the caliper moves far enough to force the piston to the bottom of the piston bore. This will back the brake pads off the rotor surface to facilitate the removal and installation of the caliper assembly.
  10.  
  11. Remove the C-clamp.
  12.  

Do not push down on the brake pedal or the piston and brake pads will return to their original positions up against the rotor.

  1. Remove the caliper support key retaining screw with a 1 / 4 in. Allen wrench. Drive the support key and spring out with a punch.
  2.  

If just the brake pads are being replaced, it is not necessary to remove the caliper assembly entirely from the vehicle. Do not remove the brake line. Rest the caliper on the front spring or other suitable support. Do not allow the brake hose to support the weight of the caliper.

  1. If the caliper is being removed in order to be rebuilt, then it is necessary to disconnect the brake fluid hose. Clean the brake fluid hose-to-caliper connection thoroughly. Remove the hose-to-caliper bolt. Cap or tape the open ends to keep dirt out. Discard the copper gaskets.
  2.  
  3. Wipe the inside of the caliper clean, including the exterior of the dust boot. Inspect the dust boot for cuts or cracks and for proper seating in the piston bore. If evidence of fluid leakage is noted, the caliper should be rebuilt.
  4.  
  5. Check the sliding surface of the caliper and anchor plate for rust or corrosion. Clean them with a wire brush and fine sandpaper; lubricate with molybdenum disulfide grease.
  6.  
  7. Place the caliper over the rotor and on the anchor plate.
  8.  

Be careful not to damage or dislodge the dust boot.

  1. Insert the support key and spring between the sliding surfaces at the rear of the caliper. Drive them into place with a punch.
  2.  
  3. Install the key retaining screw and torque it to 15 ft. lbs.
  4.  
  5. Connect the hose to the caliper, using a new copper gasket under the hose union. Torque the bolt to 25 ft. lbs.
  6.  
  7. Fill the master cylinder to within 1 / 4 in. of the rim.
  8.  
  9. Press firmly on the brake pedal several times till the pedal is firm.
  10.  
  11. Recheck the master cylinder level.
  12.  

If the brake fluid hose was disconnected, it will be necessary to bleed the hydraulic system.

1983-86 Models

CAUTION
Brake shoes contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  1. Remove 2 / 3 of the brake fluid from the front reservoir.
  2.  
  3. Raise the vehicle so that the wheel to be worked on is off the ground. Support the vehicle with jackstands.
  4.  
  5. Remove the front wheels.
  6.  
  7. Place a C-clamp on the caliper so that the solid end contacts the back of the caliper and the screw end contacts the metal part of the outboard brake pad.
  8.  
  9. Tighten the clamp until the caliper moves far enough to force the piston to the bottom of the piston bore. This will back the brake pads off the rotor surface to facilitate the removal and installation of the caliper assembly.
  10.  
  11. Remove the C-clamp.
  12.  

Do not push down on the brake pedal or the piston and brake pads will return to their original positions up against the rotor.

  1. Remove the caliper mounting pins and lift off the caliper. Don't disconnect the brake line unless the caliper is being removed for service! Don't allow the brake line to support the weight of the caliper! If you disconnect the brake line, cap it to prevent fluid loss.
  2.  
  3. Clean the caliper with a rag and solvent made for cleaning brake surfaces. Avoid disturbing the dust boot.
  4.  
  5. If there are any indications of fluid leakage, the caliper must be rebuilt.
  6.  
  7. Clean the anchor plate and caliper mounting surfaces with a wire brush.
  8.  
  9. Coat the mounting surfaces with a light coating of caliper lubricant.
  10.  
  11. Install the caliper and tighten the mounting pins to 30 ft. lbs.
  12.  
  13. Connect the hose to the caliper, using a new copper gasket under the hose union. Torque the bolt to 25 ft. lbs.
  14.  
  15. Fill the master cylinder and press firmly on the brake pedal to seat the pads.
  16.  
  17. Install the wheels, and lower the truck.
  18.  

If the brake fluid hose was disconnected, it will be necessary to bleed the hydraulic system.

OVERHAUL




CAUTION
Brake shoes contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  1. Remove the caliper assembly and remove the brake pads. If the pads are to be reused, mark their location in the caliper.
  2.  
  3. Clean the caliper exterior with clean brake fluid. Drain any residual fluid from the caliper and place it on a clean work surface.
  4.  

Removal of the caliper piston requires the use of compressed air. Do not, under any circumstances, place your fingers in front of the piston in an attempt to catch or protect it when applying compressed air to remove the piston.

  1. Pad the interior of the caliper with clean cloths. Use several cloths and pad the interior well to avoid damaging the piston when it comes out of the bore.
  2.  
  3. Insert an air nozzle into the inlet hole in the caliper and gently apply air pressure on the piston to push it out of the bore. Use only enough air pressure to ease the piston out of the bore.
  4.  
  5. Pry the dust boot out of the bore with a screwdriver. Use caution during this operation to prevent scratching the bore. Discard the dust boot.
  6.  
  7. Remove the piston seal from the piston bore and discard the seal. Use only non-scratching implements such as a wooden stick or a piece of plastic to remove the seal. Do not use a metal tool as it could very easily scratch the bore.
  8.  
  9. Remove the bleeder screw. Remove and discard the sleeves and rubber bushings from the mounting ears.
  10.  
  11. Clean all parts with clean brake fluid. Blow out all of the passages in the caliper and bleeder valve. Use only dry and filtered compressed air.
  12.  
  13. Examine the piston for defects. Replace the piston if it is nicked, scratched, corroded. Examine the caliper piston bore for the same defects as the piston. Minor stains or corrosion can be polished with a fiber brush.
  14.  
  15. Lubricate the bore and new seal with brake fluid and install the seal in the groove in the bore.
  16.  
  17. Lubricate the piston with brake fluid and install the new dust boot into the piston groove so that the fold in the boot faces the open end of the piston. Slide the metal portion of the dust boot over the open end of the piston and push the retainer toward the back of the piston until the lip on the fold seats in the piston groove. Then push the retainer portion of the boot forward until the boot is flush with the rim at the open end of the piston and snaps into place.
  18.  
  19. Insert the piston in the bore, being careful not to unseat the piston seal. Push the piston to the bottom of the bore.
  20.  
  21. Install the bleeder screw.
  22.  
  23. Connect the brake line to the caliper using new copper gaskets.
  24.  
  25. Install the brake pads.
  26.  
  27. Install the caliper. Bleed the hydraulic system.
  28.  

 
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