Jeep Wagoneer/Commando/Cherokee 1984-1998

Power Brake Boosters

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Removal & Installation



Non-ABS Equipped Models

See Figure 1

  1. Loosen, but do not remove the master cylinder retaining nuts.
  2.  
  3. Remove the instrument panel lower trim cover.
  4.  
  5. Remove the retaining clip attaching the booster pushrod to the brake pedal.
  6.  
  7. Loosen the vacuum hose clip and disconnect the hose from the check valve.
  8.  
  9. Remove the master cylinder retaining nuts and carefully move the master cylinder aside with the brake lines still attached.
  10.  
  11. Unfasten the booster retaining nuts/bolts and remove the booster.
  12.  

To install:
  1. Install the check valve and grommet in the booster.
  2.  
  3. Install the spacer on the booster (if equipped).
  4.  
  5. Position the booster on the firewall and fasten the booster mounting bolts/nuts.
  6.  
  7. Working inside the vehicle, install the nuts on the booster mounting studs. Tighten the bolts to 30 ft. lbs. (41 Nm).
  8.  
  9. Tighten the pedal pushrod bolt inner nut to 25 ft. lbs. (34 Nm) and then tighten the outer locknut to 75 inch lbs. (8 Nm).
  10.  
  11. Install the master cylinder and check for proper operation.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the power brake booster mounting

ABS Equipped Models
BENDIX ANTI-LOCK BRAKE SYSTEM

The power booster unit on the Bendix anti-lock brake system is an integral component of the master cylinder/pressure modulator/accumulator assembly. Refer to that removal procedure under the Bendix ABS portion later in this section.

TEVES MK-IV ANTI-LOCK BRAKE SYSTEM

A Diagnostic Readout Box (DRB II), or the equivalent type of scan tool, is essential to perform the bleeding of the ABS system.

  1. Pump the brake pedal until all vacuum is expelled from the booster.
  2.  
  3. Disengage the pedal travel sensor and remove the air cleaner.
  4.  
  5. Unfasten the clamps securing the reservoir hoses to the HCU pipes. Remove the hoses from the pipes.
  6.  
  7. Disengage the brake lines at the master cylinder.
  8.  
  9. Remove the combination valve bracket bolt (if necessary).
  10.  
  11. Remove the nuts attaching the master cylinder to the booster mounting. Remove the master cylinder from the vehicle.
  12.  
  13. Tag and disconnect vacuum hose at the booster check valve.
  14.  
  15. Disconnect the booster pushrod from the brake pedal.
  16.  
  17. Remove the nuts attaching the booster to the passenger compartment side of the dash panel.
  18.  
  19. Slide the booster forward and remove it from the vehicle.
  20.  

To install:
  1. Install the booster on the dash panel. Align the booster mounting studs with the holes in the panel and seat the booster.
  2.  
  3. In the passenger compartment, install the booster attaching nuts on the mounting studs. Tighten the attaching nuts to 30 ft. lbs. (41 Nm).
  4.  
  5. Install the seal on the master cylinder.
  6.  
  7. Install the pedal travel sensor and the booster pushrod.
  8.  
  9. Attach the vacuum hose to the booster check valve and install the master cylinder on the booster. Tighten the bolts to 18-22 ft. lbs. (25-30 Nm).
  10.  
  11. Engage the brake lines to the master cylinder and install the combination valve bracket bolt.
  12.  
  13. Engage the reservoir hoses to the HCU pipes.
  14.  
  15. Engage the sensor wires, bleed the brake system, install the air cleaner assembly and test drive the vehicle to verify proper brake operation.
  16.  

TEVES MK-IVg ANTI-LOCK BRAKE SYSTEM

A Diagnostic Readout Box (DRB II), or the equivalent type of scan tool, is essential to perform the bleeding of the ABS system.

  1. Disconnect the negative battery cable and remove the air cleaner assembly.
  2.  
  3. Remove the windshield washer fluid reservoir retainers and move the reservoir to one side.
  4.  
  5. Remove the master cylinder, combination valve and HCU. Refer to the proper procedures in this section and disengage the vacuum hose at the booster check valve.
  6.  
  7. In the passenger compartment, remove the booster pushrod to pedal pin retaining clip. Then slide the pushrod off the pin.
  8.  
  9. Remove the locknuts that retain the booster to the dash panel.
  10.  
  11. In the engine compartment, remove the booster by pulling it forward and tilted slightly upward.
  12.  

To install:
  1. Check the condition of the grommet that secures the check valve in the booster. If the grommet is defective it must be replaced.
  2.  
  3. Install the booster on the firewall.
  4.  
  5. In the passenger compartment, lubricate the pedal pin and bushing, then fasten the booster attaching nuts to 30 ft. lbs. (41 Nm).
  6.  
  7. Slide the booster pushrod onto the pedal pin and secure the rod to pin with the retaining clip.
  8.  
  9. In the engine compartment, engage the vacuum hose to the booster check valve.
  10.  
  11. Install the master cylinder, combination valve and HCU. Refer to the proper procedures in this section.
  12.  
  13. Bleed the brake system. Refer to the proper procedure in this section.
  14.  
  15. Install the air cleaner assembly and hoses. Test drive the vehicle and verify proper brake operation.
  16.  

 
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