Jeep Wagoneer/Commando/Cherokee 1984-1998

Calipers

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Removal & Installation



See Figures 1 and 2

This procedure applies to the removal and installation of the front and/or rear disc brake caliper assemblies.


CAUTION
Brake shoes may 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. Raise and support the vehicle safely using jackstands. Remove the wheel(s) on the side to be worked on.
  2.  

For vehicles equipped with Anti-Lock Brakes (ABS), refer to the proper procedures concerning brake system servicing.

  1. Drain a small amount of the brake fluid from the front reservoir using a suction gun or a turkey baster.
  2.  
  3. 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.
  4.  
  5. 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 of the rotor surface to facilitate the removal and installation of the caliper assembly.
  6.  
  7. Remove the C-clamp.
  8.  

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 bolts. Tilt the top of the caliper outward and lift off the rotor.
  2.  
  3. Remove the brake pads from the caliper.
  4.  

If the caliper is not being removed for overhaul, it is not necessary to remove the caliper assembly entirely from the vehicle. DO NOT remove the brake line. Suspend the caliper with a piece of wire. DO NOT allow the brake hose to support the weight of the caliper.



Click image to see an enlarged view

Fig. Fig. 1: Loosen the banjo bolt at the brake caliper ...



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Fig. Fig. 2: ... then separate from the caliper. Allow the brake fluid to drip into a container and be sure to not lose the two washers

  1. Remove the caliper fitting bolt and disconnect the brake line at the caliper. Discard the fitting bolt washers, they are not reusable. Cap or tape the open ends of the hose to keep dirt out.
  2.  

To install:
  1. Clean all the mounting holes and bushing grooves in the caliper ears. Clean the mounting bolts. Do not use abrasives on the bolts it will destroy their protective plating. Replace the bolts if they are corroded or if the threads are damaged.
  2.  
  3. Reconnect the brake hose to the caliper. Tighten the bolt to 23 ft. lbs. (31 Nm).
  4.  
  5. Install the brake pads and position the caliper over the rotor.
  6.  

Before securing the caliper, ensure the brake hose is not twisted, kinked or touching any chassis parts.

  1. Lubricate the caliper pins and bushings with silicone grease. Line up the mounting holes in the caliper and the support bracket and insert the mounting bolts. Make sure that the bolts pass under the retaining ears on the inboard shoes. Push the bolts through until they engage the holes of the outboard pad and caliper ears. Thread the bolts into the support bracket and tighten them.
  2.  


CAUTION
On models with manual/power brakes, pump the pedal until the caliper pistons and brake shoes are seated. On models with anti-lock brakes, turn the ignition ON and allow the booster pump to build pressure. Pump the brake pedal until the shoes are seated and the indicator lights turn off.

  1. Fill the master cylinder with brake fluid and pump the brake pedal to seat the pads.
  2.  
  3. Install the wheel assembly and lower the vehicle. Check the level of the brake fluid in the master cylinder and fill as necessary.
  4.  

OVERHAUL



See Figures 3 through 9

Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.

      Click image to see an enlarged view

      Fig. Fig. 3: For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



      Click image to see an enlarged view

      Fig. Fig. 4: Withdraw the piston from the caliper bore

    4.  

  2.  
  3. For the second method, you must rotate the piston to retract it from the caliper.
  4.  
  5. If equipped, remove the anti-rattle clip.
  6.  



Click image to see an enlarged view

Fig. Fig. 5: On some vehicles, you must remove the anti-rattle clip

  1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  2.  



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Fig. Fig. 6: Use a prytool to carefully pry around the edge of the boot ...



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Fig. Fig. 7: ... then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  
  3. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  4.  
  5. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  6.  
  7. Use crocus cloth to polish out light corrosion from the piston and bore.
  8.  
  9. Clean all parts with denatured alcohol and dry with compressed air.
  10.  

To assemble:
  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
  6.  
  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  



Click image to see an enlarged view

Fig. Fig. 8: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Install the caliper in the vehicle.
  2.  
  3. Install the wheel and tire assembly, then carefully lower the vehicle.
  4.  
  5. Properly bleed the brake system.
  6.  



Click image to see an enlarged view

Fig. Fig. 9: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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