Jeep Wrangler/YJ 1987-1995 Repair Guide

Brake Pads

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REMOVAL & INSTALLATION



1987-89 Vehicles

See Figures 1 through 8


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. Remove the wheel(s) on the side to be worked on.
  2.  
  3. Drain a small amount of the brake fluid from the front reservoir. Use the bleeder screw at the front outlet port to drain the fluid.
  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 of 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 both of the Allen head mounting bolts. Tilt the top of the caliper outward and lift off the rotor.
  2.  



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Fig. Fig. 1: Removing the caliper mounting pins



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Fig. Fig. 2: Removing the caliper from the support bracket



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Fig. Fig. 3: Removing the outboard shoe



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Fig. Fig. 4: Removing the inboard shoe



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Fig. Fig. 5: Clean and lubricate the slide surfaces



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Fig. Fig. 6: Installing the anti-rattle clip and inboard brake shoe



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Fig. Fig. 7: Installing the outboard brake shoe



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Fig. Fig. 8: Caliper components

  1. Hold the anti-rattle clip against the caliper anchor plate and remove the outboard brake pad.
  2.  
  3. Remove the inboard pad and its anti-rattle clip.
  4.  
  5. Use a piece of wire to support the caliper so that no tension is placed on the brake hose. DO NOT allow the caliper to hang by the brake hose.
  6.  

To install:
  1. Clean all the mounting holes and bushing grooves in the caliper ears. Clean the mounting bolts. Replace the bolts if they are corroded or if the threads are damaged. 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.
  2.  

Do not use abrasives on the bolts, in order not to destroy their protective plating. You should not use compressed air to clean the inside of the caliper, as it may unseat the dust boot seal.

  1. Install the inboard anti-rattle clip on the trailing end of the anchor plate. The split end of the clip must face away from the rotor.
  2.  
  3. Install the inboard pad in the caliper. The pad must lay flat against the piston.
  4.  
  5. Install the outboard pad in the caliper while holding the anti-rattle clip.
  6.  
  7. With the pads installed, position the caliper over the rotor.
  8.  

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 to 30 ft. lbs. (41 Nm).
  2.  


WARNING
On models without anti-lock 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, then 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.  

1990-95 Vehicles

See Figures 9 through 21


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. 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.  


WARNING
Do not allow the clamp screw to bear directly on the outboard shoe retainer spring. Use a wood or metal spacer between the shoe and clamp screw.

  1. 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.
  2.  
  3. Remove the C-clamp.
  4.  

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 slide pins (bolts) and lift off the caliper. Don't disconnect the brake line! Don't allow the brake line to support the weight of the caliper! Attach a support wire to the caliper and hang it from the vehicle suspension.
  2.  
  3. To remove the outboard shoe, press one end of the shoe inward to disengage the shoe lug and rotate the shoe upward until the spring retainer clears the caliper. Then press the opposite end of the shoe inward to disengage the opposite shoe lug and rotate the shoe up and out of the caliper.
  4.  
  5. Remove the inboard pad, grasp the ends of the shoe and tilt the shoe outward to release the springs from the caliper piston, then remove the pad from the caliper.
  6.  
  7. Clean the caliper with a rag and solvent made for cleaning brake surfaces. Avoid disturbing the dust boot.
  8.  
  9. If there are any indications of fluid leakage, the caliper must be rebuilt.
  10.  
  11. Clean the anchor plate and caliper mounting surfaces with a wire brush.
  12.  
  13. Coat the mounting surfaces with a light coating of caliper lubricant.
  14.  
  15. Lubricate the caliper mounting bolts and bushings with GE 661 or Dow 111 or equivalent silicone grease.
  16.  
  17. Install the inboard, then the outboard pads. Check the position of the springs. Make sure that they are seated properly and that the spring ends are in contact with the pad mounting ears.
  18.  


WARNING
Avoid damaging the caliper piston dust boot while installing the pads!

  1. Install the caliper and tighten the mounting pins to 7-15 ft. lbs. (10-20 Nm).
  2.  
  3. Fill the master cylinder and press firmly on the brake pedal to seat the pads.
  4.  
  5. Install the wheels, and lower the vehicle.
  6.  



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Fig. Fig. 9: View of the brake caliper and rotor assembly -- 1990-94



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Fig. Fig. 10: C-clamp attachment for bottoming the caliper piston in the bore -- 1990-94



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Fig. Fig. 11: Position the C-clamp screw on the outboard shoe as shown, using a spacer between the shoe retainer spring and the clamp screw -- 1990-94



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Fig. Fig. 12: Use a socket to loosen the caliper slide pins (mounting bolts)



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Fig. Fig. 13: Removing the caliper slide pins (mounting bolts)



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Fig. Fig. 14: Tilt the caliper outboard to remove



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Fig. Fig. 15: Carefully lift the caliper off the rotor and knuckle



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Fig. Fig. 16: Attach a support wire to the caliper and hang it from the vehicle suspension to relieve tension on the brake hose



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Fig. Fig. 17: Removing the outboard brake shoe



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Fig. Fig. 18: Removing the inboard brake shoe



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Fig. Fig. 19: Caliper lubrication points



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Fig. Fig. 20: Installing the inboard brake shoe



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Fig. Fig. 21: Installing the outboard brake shoe

 
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