ZJ BRAKES 5-1

BRAKES
CONTENTS

page page

ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . . 34 BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . 1

BASE BRAKE SYSTEM

INDEX
page page

GENERAL INFORMATION COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . 14

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 2 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . 16
SERVICE WARNINGS & CAUTIONS . . . . . . . . . . 2 DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 19
DESCRIPTION AND OPERATION DISC BRAKESHOE . . . . . . . . . . . . . . . . . . . . . . 17
BRAKE HOSES AND LINES . . . . . . . . . . . . . . . . . 5 FRONT PARKING BRAKE CABLE . . . . . . . . . . . 22
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 15
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 3 PARKING BRAKE CAM AND LEVER . . . . . . . . . 24
FRONT DISC BRAKES . . . . . . . . . . . . . . . . . . . . . 4 PARKING BRAKE HAND LEVER . . . . . . . . . . . . 21
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 3 PARKING BRAKESHOES . . . . . . . . . . . . . . . . . . 23
PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 5 POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . 15
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 2 REAR DISC BRAKE CALIPER . . . . . . . . . . . . . . 19
REAR DISC BRAKES . . . . . . . . . . . . . . . . . . . . . . 4 REAR DISC BRAKE ROTOR . . . . . . . . . . . . . . . 21
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . 2 REAR DISC BRAKESHOES . . . . . . . . . . . . . . . . 20
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 2 REAR PARKING BRAKE CABLE . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING SPLASH SHIELD/CALIPER BRACKET/LEVER
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . 5 BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . 11 STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 14
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . . 11 DISASSEMBLY AND ASSEMBLY
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 9 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . 28
FRONT DISC BRAKE ROTOR . . . . . . . . . . . . . . . 9 MASTER CYLINDER RESERVOIR . . . . . . . . . . . 27
MASTER CYLINDER/POWER BOOSTER . . . . . . . 8 REAR DISC BRAKE CALIPER . . . . . . . . . . . . . . 30
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 10 CLEANING AND INSPECTION
REAR DISC BRAKE ROTOR . . . . . . . . . . . . . . . 10 CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . 8 ADJUSTMENTS
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 8 PARKING BRAKE CABLE TENSIONER . . . . . . . 32
SERVICE PROCEDURES PARKING BRAKESHOE . . . . . . . . . . . . . . . . . . . 32
BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . 12 STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 32
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . 11 SPECIFICATIONS
BRAKE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . . 33
DISC ROTOR MACHINING . . . . . . . . . . . . . . . . . 12 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . 32
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 11 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL AND INSTALLATION SPECIAL TOOLS
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . 14 BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5-2 BRAKES ZJ

GENERAL INFORMATION CAUTION: Use Mopar brake fluid, or an equivalent

quality fluid meeting SAE/DOT standards J1703 and
BRAKE SYSTEM DOT 3. Brake fluid must be clean and free of con-
All vehicles are equipped with power assist four- taminants. Use fresh fluid from sealed containers
wheel disc brakes. Antilock (ABS) brakes are also only to ensure proper antilock component opera-
standard equipment on all models. tion.
Single piston, disc brake calipers are used front Use Mopar multi-mileage or high temperature
and rear. Ventilated disc brake rotors are used at the grease to lubricate caliper slide surfaces, drum
front and solid rotors are used at the rear. brake pivot pins, and shoe contact points on the
Power brake assist is supplied by a vacuum oper- backing plates. Use multi-mileage grease or GE 661
ated, dual diaphragm power brake booster. or Dow 111 silicone grease on caliper bushings and
The master cylinder used for all applications has slide pins to ensure proper operation.
an aluminum body and nylon reservoir with single
filler cap.
A combination valve is used for all applications. DESCRIPTION AND OPERATION
The valve contains a pressure differential switch and
rear brake proportioning valve. BRAKE PEDAL
A suspended-type brake pedal is used, the pedal
SERVICE WARNINGS & CAUTIONS pivots on a shaft mounted in the pedal support
bracket. The bracket is attached to the dash and
WARNING: DUST AND DIRT ACCUMULATING ON
instrument panels.
BRAKE PARTS DURING NORMAL USE MAY CON-
The brake pedal is a serviceable component. The
TAIN ASBESTOS FIBERS. BREATHING EXCESSIVE
pedal, pivot pin, sleeve, pedal bushings and spacers/
CONCENTRATIONS OF ASBESTOS FIBERS CAN
washers are all replaceable parts. The pedal bracket
CAUSE SERIOUS BODILY HARM. EXERCISE CARE
can also be replaced when necessary.
WHEN SERVICING BRAKE PARTS. DO NOT CLEAN
BRAKE PARTS WITH COMPRESSED AIR OR BY
STOP LAMP SWITCH
DRY BRUSHING. USE A VACUUM CLEANER SPE-
The plunger type stop lamp switch is mounted on a
CIFICALLY DESIGNED FOR THE REMOVAL OF
bracket attached to the brake pedal support. The
ASBESTOS FIBERS FROM BRAKE COMPONENTS.
switch can be adjusted when necessary.
IF A SUITABLE VACUUM CLEANER IS NOT AVAIL-
ABLE, CLEANING SHOULD BE DONE WITH A
RED BRAKE WARNING LAMP
WATER DAMPENED CLOTH. DO NOT SAND, OR
A red warning lamp is used for the service brake
GRIND BRAKE LINING UNLESS EQUIPMENT USED
portion of the hydraulic system. The lamp is located
IS DESIGNED TO CONTAIN THE DUST RESIDUE.
in the instrument panel.
DISPOSE OF ALL RESIDUE CONTAINING ASBES-
The red warning light alerts the driver if a pres-
TOS FIBERS IN SEALED BAGS OR CONTAINERS
sure differential exists between the front and rear
TO MINIMIZE EXPOSURE TO YOURSELF AND OTH-
hydraulic systems. The light also alerts the driver
ERS. FOLLOW PRACTICES PRESCRIBED BY THE
when the parking brakes are applied.
OCCUPATIONAL SAFETY AND HEALTH ADMINIS-
TRATION AND THE ENVIRONMENTAL PROTECTION
POWER BRAKE BOOSTER
AGENCY FOR THE HANDLING, PROCESSING, AND
The booster assembly consists of a housing divided
DISPOSITION OF DUST OR DEBRIS THAT MAY
into separate chambers by two internal diaphragms.
CONTAIN ASBESTOS FIBERS.
The outer edge of each diaphragm is attached to the
booster housing. The diaphragms are connected to
CAUTION: Never use gasoline, kerosene, alcohol, the booster primary push rod.
motor oil, transmission fluid, or any fluid containing Two push rods are used in the booster. The pri-
mineral oil to clean the system components. These mary push rod connects the booster to the brake
fluids damage rubber cups and seals. Use only pedal. The secondary push rod connects the booster
fresh brake fluid or Mopar brake cleaner to clean or to the master cylinder to stroke the cylinder pistons.
flush brake system components. These are the only The atmospheric inlet valve is opened and closed
cleaning materials recommended. If system contam- by the primary push rod. Booster vacuum supply is
ination is suspected, check the fluid for dirt, discol- through a hose attached to an intake manifold fitting
oration, or separation into distinct layers. Drain and at one end and to the booster check valve at the
flush the system with new brake fluid if contamina- other. The vacuum check valve in the booster housing
tion is suspected. is a one-way device that prevents vacuum leak back.
ZJ BRAKES 5-3
DESCRIPTION AND OPERATION (Continued)
Power assist is generated by utilizing the pressure MASTER CYLINDER
differential between normal atmospheric pressure The master cylinder has a removable nylon reser-
and a vacuum. The vacuum needed for booster oper- voir (Fig. 2). The cylinder body is made of aluminum
ation is taken directly from the engine intake mani- and contains a primary and secondary piston assem-
fold. The entry point for atmospheric pressure is bly. The cylinder body including the piston assem-
through a filter and inlet valve at the rear of the blies are not serviceable. If diagnosis indicates an
housing (Fig. 1). internal problem with the cylinder body, it must be
The chamber areas forward of the booster dia- replaced as an assembly. The reservoir and grommets
phragms are exposed to vacuum from the intake are the only replaceable parts on the master cylinder.
manifold. The chamber areas to the rear of the dia-
phragms, are exposed to normal atmospheric pres- COMBINATION VALVE
sure of 101.3 kilopascals (14.7 pounds/square in.). The combination valve contains a pressure differ-
Brake pedal application causes the primary push ential valve and switch and a rear brake proportion-
rod to open the atmospheric inlet valve. This exposes ing valve. The valve is not repairable. It must be
the area behind the diaphragms to atmospheric pres- replaced if diagnosis indicates this is necessary.
sure. The resulting pressure differential provides the The pressure differential switch is connected to the
extra apply pressure for power assist. brake warning light. The switch is actuated by move-
ment of the switch valve. The switch monitors fluid

Fig. 1 Power Brake Booster

5-4 BRAKES ZJ
DESCRIPTION AND OPERATION (Continued)

Fig. 2 Master Cylinder

pressure in the separate front/rear brake hydraulic
circuits.
A decrease or loss of fluid pressure in either
hydraulic circuit will cause the switch valve to shut-
tle to the low pressure side. Movement of the valve
pushes the switch plunger upward. This action closes
the switch internal contacts completing the electrical Fig. 3 Brake Caliper Operation
circuit to the red warning light. The switch valve will Application and release of the brake pedal gener-
remain in an actuated position until repairs are ates only a very slight movement of the caliper and
made. piston. Upon release of the pedal, the caliper and pis-
The rear proportioning valve is used to balance ton return to a rest position. The brakeshoes do not
front-rear brake action. The valve allows normal retract an appreciable distance from the rotor. In
fluid flow during moderate effort brake stops. The fact, clearance is usually at, or close to zero. The rea-
valve only controls (meters) fluid flow during high sons for this are to keep road debris from getting
effort brake stops. between the rotor and lining and in wiping the rotor
surface clear each revolution.
FRONT DISC BRAKES The caliper piston seal controls the amount of pis-
The calipers are a single piston type. The calipers ton extension needed to compensate for normal lining
are free to slide laterally, this allows continuous com- wear.
pensation for lining wear. During brake application, the seal is deflected out-
When the brake are applied fluid pressure is ward by fluid pressure and piston movement (Fig. 4).
exerted against the caliper piston. The fluid pressure When the brakes (and fluid pressure) are released,
is exerted equally and in all directions. This means the seal relaxes and retracts the piston.
pressure exerted against the caliper piston and The amount of piston retraction is determined by
within the caliper bore will be equal (Fig. 3). brakelining wear. Generally the amount is just
Fluid pressure applied to the piston is transmitted enough to maintain contact between the piston and
directly to the inboard brakeshoe. This forces the inboard brakeshoe.
shoe lining against the inner surface of the disc
brake rotor. At the same time, fluid pressure within REAR DISC BRAKES
the piston bore forces the caliper to slide inward on Rear disc brake components consist of single pis-
the mounting bolts. This action brings the outboard ton, floating-type, rear disc brake calipers and solid
brakeshoe lining into contact with the outer surface rotors.
of the disc brake rotor. The rear calipers are mounted in a bracket
In summary, fluid pressure acting simultaneously attached to the rear axle tube flange (Fig. 5). The
on both piston and caliper, produces a strong clamp- calipers are secured to the bracket with mounting
ing action. When sufficient force is applied, friction bolts. The bracket also secures the rear disc brake
will stop the rotors from turning and bring the vehi- rotor splash shield to the tube flange.
cle to a stop. The rotor and splash shield used for rear disc
brake applications are unique. The parking brake-
ZJ BRAKES 5-5
DESCRIPTION AND OPERATION (Continued)
PARKING BRAKES
The parking brakes are operated by a cable and
hand lever system. Three cables are used, consisting
of one front cable and two rear cables. All three
cables are interconnected at the cable tensioner and
equalizer mechanism. The front cable is connected to
the hand lever and the rear cables are connected to
the brakeshoes. Cable adjustment is performed at the
tensioner which is attached to the front cable.
A separate set of brakeshoes are used for parking
brake operation. The shoes are mounted on the disc
Fig. 4 Lining Wear Compensation By Piston Seal brake splash shield and are enclosed within the com-
bination disc brake rotor and parking brake drum.
shoes are mounted on the splash shield. The disc The rear cables are connected to a cam and lever
brake rotor has a built in brake drum surface for the mechanism, the cam and lever operates the shoes.
parking brakeshoes (Fig. 6). Parking brakeshoe ser- The cable is connected to the lever by a rectangu-
vice is covered in the parking brake service section. lar eyelet on the cable end. A retainer on the cable
The outboard shoe now has an anti-rattle spring secures it in a bracket attached to the rear of the cal-
attached at the shoe rear. A wear strip is mounted to iper bracket. The lever is mounted on the floorpan
the inboard shoe. adjacent to the driver.

NOTE: Parking brake cable adjustment is con-

trolled by a tensioner mechanism. The cable ten-
sioner, once adjusted at the factory, will not need
further adjustment under normal circumstances.
There are only time a adjustment is required is
when the tensioner, or cables have been replaced
or disconnected.

BRAKE HOSES AND LINES

Flexible rubber hose is used at both front brakes
and at the rear axle junction block. Double walled
steel tubing is used to connect the master cylinder to
the major hydraulic braking components and then to
the flexible rubber hoses.

DIAGNOSIS AND TESTING

BASE BRAKE SYSTEM
Base brake components consist of the brakeshoes,
calipers, wheel cylinders, brake drums, rotors, brake-
Fig. 5 Rear Disc Brake Caliper Mounting lines, master cylinder, booster, and parking brake
components.
Brake diagnosis involves determining if the prob-
lem is related to a mechanical, hydraulic, or vacuum
operated component.
The first diagnosis step is the preliminary check.

PRELIMINARY BRAKE CHECK

(1) Check condition of tires and wheels. Damaged
wheels and worn, damaged, or underinflated tires
can cause pull, shudder, vibration, and a condition
similar to grab.
Fig. 6 Rear Disc Brake Rotor (2) If complaint was based on noise when braking,
check suspension components. Jounce front and rear
5-6 BRAKES ZJ
DIAGNOSIS AND TESTING (Continued)
of vehicle and listen for noise that might be caused SPONGY PEDAL
by loose, worn or damaged suspension or steering A spongy pedal is most often caused by air in the
components. system. However, thin brake drums or substandard
(3) Inspect brake fluid level and condition. Note brake lines and hoses can also cause a spongy pedal.
that the front disc brake reservoir fluid level will The proper course of action is to bleed the system, or
decrease in proportion to normal lining wear. Also replace thin drums and suspect quality brake lines
note that brake fluid tends to darken over time. and hoses.
This is normal and should not be mistaken for
contamination. HARD PEDAL OR HIGH PEDAL EFFORT
(a) If fluid level is abnormally low, look for evi- A hard pedal or high pedal effort may be due to
dence of leaks at calipers, wheel cylinders, brake- lining that is water soaked, contaminated, glazed, or
lines, and master cylinder. badly worn. The power booster or check valve could
(b) If fluid appears contaminated, drain out a also be faulty.
sample. System will have to be flushed if fluid is
separated into layers, or contains a substance PEDAL PULSATION
other than brake fluid. The system seals and cups Pedal pulsation is caused by components that are
will also have to be replaced after flushing. Use loose, or beyond tolerance limits.
clean brake fluid to flush the system. The primary cause of pulsation are disc brake
(4) Check parking brake operation. Verify free rotors with excessive lateral runout or thickness vari-
movement and full release of cables and pedal. Also ation, or out of round brake drums. Other causes are
note if vehicle was being operated with parking loose wheel bearings or calipers and worn, damaged
brake partially applied. tires.
(5) Check brake pedal operation. Verify that pedal
does not bind and has adequate free play. If pedal NOTE: Some pedal pulsation may be felt during
lacks free play, check pedal and power booster for ABS activation.
being loose or for bind condition. Do not road test
until condition is corrected.
BRAKE DRAG
(6) If components checked appear OK, road test
the vehicle. Brake drag occurs when the lining is in constant
contact with the rotor or drum. Drag can occur at one
ROAD TESTING wheel, all wheels, fronts only, or rears only.
(1) If complaint involved low brake pedal, pump Drag is a product of incomplete brakeshoe release.
pedal and note if it comes back up to normal height. Drag can be minor or severe enough to overheat the
(2) Check brake pedal response with transmission linings, rotors and drums.
in Neutral and engine running. Pedal should remain Minor drag will usually cause slight surface char-
firm under constant foot pressure. ring of the lining. It can also generate hard spots in
(3) During road test, make normal and firm brake rotors and drums from the overheat-cool down pro-
stops in 25-40 mph range. Note faulty brake opera- cess. In most cases, the rotors, drums, wheels and
tion such as low pedal, hard pedal, fade, pedal pulsa- tires are quite warm to the touch after the vehicle is
tion, pull, grab, drag, noise, etc. stopped.
Severe drag can char the brake lining all the way
PEDAL FALLS AWAY through. It can also distort and score rotors and
A brake pedal that falls away under steady foot drums to the point of replacement. The wheels, tires
pressure is generally the result of a system leak. The and brake components will be extremely hot. In
leak point could be at a brakeline, fitting, hose, or severe cases, the lining may generate smoke as it
caliper/wheel cylinder. Internal leakage in the master chars from overheating.
cylinder caused by worn or damaged piston cups, Common causes of brake drag are:
may also be the problem cause. • Seized or improperly adjusted parking brake
If leakage is severe, fluid will be evident at or cables.
around the leaking component. However, internal • Loose/worn wheel bearing.
leakage in the master cylinder may not be physically • Seized caliper or wheel cylinder piston.
evident. • Caliper binding on corroded bushings or rusted
slide surfaces.
LOW PEDAL • Loose caliper mounting bracket.
If a low pedal is experienced, pump the pedal sev- • Drum brakeshoes binding on worn/damaged sup-
eral times. If the pedal comes back up, worn lining, port plates.
rotors, or drums are the most likely causes. • Misassembled components.
ZJ BRAKES 5-7
DIAGNOSIS AND TESTING (Continued)
If brake drag occurs at all wheels, the problem dirt contaminated, cleaning and/or replacement will
may be related to a blocked master cylinder return be necessary.
port, or faulty power booster (binds-does not release).
BRAKE SQUEAK/SQUEAL
BRAKE FADE Brake squeak or squeal may be due to linings that
Brake fade is usually a product of overheating are wet or contaminated with brake fluid, grease, or
caused by brake drag. However, brake overheating oil. Glazed linings and rotors with hard spots can
and resulting fade can also be caused by riding the also contribute to squeak. Dirt and foreign material
brake pedal, making repeated high deceleration stops embedded in the brake lining will also cause squeak/
in a short time span, or constant braking on steep squeal.
mountain roads. Refer to the Brake Drag information A very loud squeak or squeal is frequently a sign of
in this section for causes. severely worn brake lining. If the lining has worn
through to the brakeshoes in spots, metal-to-metal
BRAKE PULL contact occurs. If the condition is allowed to continue,
Front brake pull condition could result from: rotors and drums can become so scored that replace-
• Contaminated lining in one caliper ment is necessary.
• Seized caliper piston
• Binding caliper BRAKE CHATTER
• Loose caliper Brake chatter is usually caused by loose or worn
• Rusty adapter/caliper slide surfaces components, or glazed/burnt lining. Rotors with hard
• Improper brakeshoes spots can also contribute to chatter. Additional causes
• Damaged rotor of chatter are out-of-tolerance rotors, brake lining not
A worn, damaged wheel bearing or suspension securely attached to the shoes, loose wheel bearings
component are further causes of pull. A damaged and contaminated brake lining.
front tire (bruised, ply separation) can also cause
pull. THUMP/CLUNK NOISE
A common and frequently misdiagnosed pull condi- Thumping or clunk noises during braking are fre-
tion is where direction of pull changes after a few quently not caused by brake components. In many
stops. The cause is a combination of brake drag fol- cases, such noises are caused by loose or damaged
lowed by fade at one of the brake units. steering, suspension, or engine components. However,
As the dragging brake overheats, efficiency is so calipers that bind on the slide surfaces can generate
reduced that fade occurs. Since the opposite brake a thump or clunk noise. In addition, worn out,
unit is still functioning normally, its braking effect is improperly adjusted, or improperly assembled rear
magnified. This causes pull to switch direction in brakeshoes can also produce a thump noise.
favor of the normally functioning brake unit.
An additional point when diagnosing a change in BRAKELINING CONTAMINATION
pull condition concerns brake cool down. Remember Brakelining contamination is mostly a product of
that pull will return to the original direction, if the leaking calipers or wheel cylinders, worn seals, driv-
dragging brake unit is allowed to cool down (and is ing through deep water puddles, or lining that has
not seriously damaged). become covered with grease and grit during repair.
Contaminated lining should be replaced to avoid fur-
REAR BRAKE GRAB OR PULL ther brake problems.
Rear grab or pull is usually caused by improperly
adjusted or seized parking brake cables, contami- WHEEL AND TIRE PROBLEMS
nated lining, bent or binding shoes and support Some conditions attributed to brake components
plates, or improperly assembled components. This is may actually be caused by a wheel or tire problem.
particularly true when only one rear wheel is A damaged wheel can cause shudder, vibration and
involved. However, when both rear wheels are pull. A worn or damaged tire can also cause pull.
affected, the master cylinder, proportioning valve, or Severely worn tires with very little tread left can
RWAL valve could be at fault. produce a grab-like condition as the tire loses and
recovers traction. Flat-spotted tires can cause vibra-
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP tion and generate shudder during brake operation. A
WATER PUDDLES tire with internal damage such as a severe bruise,
This condition is generally caused by water soaked cut, or ply separation can cause pull and vibration.
lining. If the lining is only wet, it can be dried by
driving with the brakes very lightly applied for a
mile or two. However, if the lining is both soaked and
5-8 BRAKES ZJ
DIAGNOSIS AND TESTING (Continued)
STOP LAMP SWITCH the front or rear wheel brake hydraulic circuit. It will
Stop lamp switch operation can be tested with an also illuminate at startup as part of a bulb check.
ohmmeter. The ohmmeter is used to check continuity If the light comes on, first verify that the parking
between the pin terminals at different plunger posi- brakes are fully released. Then check pedal action
tions (Fig. 7). and fluid level. If a problem is confirmed, inspect the
brake hydraulic system for leaks.
NOTE: The switch wire harness must be discon-
nected before testing switch continuity. MASTER CYLINDER/POWER BOOSTER
(1) Start engine and check booster vacuum hose
connections. A hissing noise indicates vacuum leak.
SWITCH CIRCUIT IDENTIFICATION Correct any vacuum leak before proceeding.
• Terminals 1 and 2 are for brake sensor circuit. (2) Stop engine and shift transmission into Neu-
• Terminals 5 and 6 are for the stop lamp circuit. tral.
• Terminals 3 and 4 are for the speed control cir- (3) Pump brake pedal until all vacuum reserve in
cuit. booster is depleted.
(4) Press and hold brake pedal under light foot
pressure. The pedal should hold firm, if the pedal
falls away master cylinder is faulty (internal leak-
age).
(5) Start engine and note pedal action it should
falls away slightly under light foot pressure then
holds firm. If no pedal action is discernible, power
booster, vacuum supply, or vacuum check valve is
faulty. Proceed to the POWER BOOSTER VACUUM
TEST.
(6) If the POWER BOOSTER VACUUM TEST
passes, rebuild booster vacuum reserve as follows:
Release brake pedal. Increase engine speed to 1500
rpm, close the throttle and immediately stop turn off
ignition to stop engine.
(7) Wait a minimum of 90 seconds and try brake
Fig. 7 Stop Lamp Switch Terminal Identification action again. Booster should provide two or more vac-
uum assisted pedal applications. If vacuum assist is
SWITCH CONTINUITY TEST
not provided, booster is faulty.
(1) Check continuity between terminal pins 5 and
6 as follows: POWER BOOSTER VACUUM TEST
(a) Pull plunger all the way out to fully extended (1) Connect vacuum gauge to booster check valve
position. with short length of hose and T-fitting (Fig. 8).
(b) Attach test leads to pins 5 and 6 and note (2) Start and run engine at curb idle speed for one
ohmmeter reading. minute.
(c) If continuity exists, proceed to next test. (3) Observe the vacuum supply. If vacuum supply
Replace switch if meter indicates lack of continuity is not adequate, repair vacuum supply.
(shorted or open). (4) Clamp hose shut between vacuum source and
(2) Check continuity between terminal pins 1 and check valve.
2 and pins 3 and 4 as follows: (5) Stop engine and observe vacuum gauge.
(a) Push switch plunger inward to fully (6) If vacuum drops more than one inch HG (33
retracted position. millibars) within 15 seconds, booster diaphragm or
(b) Attach test leads to pins 1 and 2 and note check valve is faulty.
ohmmeter reading.
(c) If continuity exists, switch is OK. Replace POWER BOOSTER CHECK VALVE TEST
switch if meter indicates lack of continuity (switch (1) Disconnect vacuum hose from check valve.
is open). (2) Remove check valve and valve seal from
booster.
RED BRAKE WARNING LAMP (3) Use a hand operated vacuum pump for test.
The red warning lamp illuminates when the park- (4) Apply 15-20 inches vacuum at large end of
ing brakes are applied and when there is a leak in check valve (Fig. 9).
ZJ BRAKES 5-9
DIAGNOSIS AND TESTING (Continued)
Pressure Differential Switch
(1) Have helper sit in drivers seat to apply brake
pedal and observe red brake warning light.
(2) Raise vehicle on hoist.
(3) Connect bleed hose to a rear wheel cylinder
and immerse hose end in container partially filled
with brake fluid.
(4) Have helper press and hold brake pedal to floor
and observe warning light.
(a) If warning light illuminates, switch is operat-
ing correctly.
(b) If light fails to illuminate, check circuit fuse,
bulb, and wiring. The parking brake switch can be
used to aid in identifying whether or not the brake
light bulb and fuse is functional. Repair or replace
parts as necessary and test differential pressure
switch operation again.
(5) If warning light still does not illuminate,
switch is faulty. Replace combination valve assembly,
bleed brake system and verify proper switch and
valve operation.
Fig. 8 Typical Booster Vacuum Test Connections
FRONT DISC BRAKE ROTOR
(5) Vacuum should hold steady. If gauge on pump
indicates vacuum loss, check valve is faulty and ROTOR MINIMUM THICKNESS
should be replaced. Rotor minimum usable thickness is 22.7 mm (0.89
in.). Do not resurface a rotor if machining would
cause thickness to fall below this limit.
Measure rotor thickness at the center of the brake-
shoe contact surface. Replace the rotor if worn below
minimum thickness, or if refinishing would reduce
thickness below the allowable minimum.

FRONT ROTOR THICKNESS VARIATION

Variations in rotor thickness will cause pedal pul-
sation, noise and shudder.
Measure rotor thickness at four to six points
around the rotor face. Position the micrometer
approximately 3/4 inch from the rotor outer circum-
ference for each measurement (Fig. 10).
Thickness should not vary by more than 0.013 mm
(0.0005 in.) from point to point on the rotor. Refinish
or replace the rotor if necessary.
Fig. 9 Vacuum Check Valve And Seal
COMBINATION VALVE FRONT ROTOR LATERAL RUNOUT
Check rotor lateral runout whenever pedal pulsa-
Metering Valve tion, or rapid, uneven brakelining wear has occurred.
Metering valve operation can be checked visually The rotor must be securely clamped to the hub to
and with the aid of a helper. Observe the metering ensure an accurate runout measurement. Secure the
valve stem while a helper applies and releases the rotor with the wheel nuts and 4 or 5 large diameter
brakes. If the valve is operating correctly, the stem flat washers on each stud.
will extend slightly when the brakes are applied and Use a dial indicator to check lateral runout (Fig.
retract when the brakes are released. If the valve is 11).
faulty, replace the entire combination valve as an Maximum allowable rotor lateral runout is 0.13
assembly. mm (0.005 in.).
5 - 10 BRAKES ZJ
DIAGNOSIS AND TESTING (Continued)

Fig. 12 Thickness Specification On Rear Rotor

Measure rotor thickness at four to six points
Fig. 10 Measuring Rotor Thickness Variation
around the rotor face. Position the micrometer
approximately 3/4 inch from the rotor outer circum-
ference for each measurement (Fig. 10).
Thickness should not vary by more than 0.0254
mm (0.001 in.) from point to point on the rotor.
Refinish or replace the rotor if necessary.

REAR ROTOR LATERAL RUNOUT

Check rotor lateral runout whenever diagnosis
indicates pedal pulsation and rapid, uneven brakelin-
ing wear.
The rotor must be securely clamped to the hub to
ensure an accurate runout measurement. Secure the
rotor with the wheel nuts and 4 or 5 large diameter
flat washers on each stud.
Use a dial indicator to check lateral runout (Fig.
11). Maximum allowable lateral runout is 0.13 mm
(0.005 in.).

Fig. 11 Checking Rotor Lateral Runout PARKING BRAKE

REAR DISC BRAKE ROTOR NOTE: Parking brake adjustment is controlled by a
cable tensioner. Once the tensioner is adjusted at
ROTOR MINIMUM THICKNESS
the factory, it should not require further attention.
Minimum usable thickness of the rear disc brake
However, there are two instances when adjustment
rotor is 9.5 mm (0.374 in.). The thickness specifica-
will be required. The first is when a new tensioner,
tion is located on the edge of the parking brake drum
or cables have been installed. And the second, is
section of the rotor (Fig. 12).
when the tensioner and cables are disconnected for
Never resurface a rotor if machining would cause
access to other brake components.
thickness to fall below this limit.
Measure rotor thickness at the center of the brake- The parking brake switch is in circuit with the red
shoe contact surface. Replace the rotor if worn below warning lamp in the dash. The switch will cause the
minimum thickness, or if refinishing would reduce lamp to illuminate only when the parking brakes are
thickness below the allowable minimum. applied. If the lamp remains on after parking brake
release, the switch or wires are faulty, or cable ten-
REAR ROTOR THICKNESS VARIATION
sioner adjustment is incorrect.
Variations in rotor thickness will cause pedal pul-
sation, noise and shudder.
ZJ BRAKES 5 - 11
DIAGNOSIS AND TESTING (Continued)
If the red lamp comes on while the vehicle is in The steel brake lines should be inspected periodi-
motion and brake pedal height decreases, a fault has cally for evidence of corrosion, twists, kinks, leaks, or
occurred in the front or rear brake hydraulic system. other damage. Heavily corroded lines will eventually
In most cases, the actual cause of an improperly rust through causing leaks. In any case, corroded or
functioning parking brake (too loose/too tight/wont damaged brake lines should be replaced.
hold), can be traced to a parking brake component. Factory replacement brake lines and hoses are rec-
ommended to ensure quality, correct length and supe-
NOTE: The leading cause of improper parking rior fatigue life. Care should be taken to make sure
brake operation, is excessive clearance between the that brake line and hose mating surfaces are clean
parking brakeshoes and the shoe braking surface. and free from nicks and burrs. Also remember that
Excessive clearance is a result of lining and/or right and left brake hoses are not interchangeable.
drum wear, drum surface machined oversize, or Use new copper seal washers at all caliper connec-
inoperative adjuster components. tions. Be sure brake line connections are properly
made (not cross threaded) and tightened to recom-
Excessive parking brake lever travel (sometimes mended torque.
described as a loose lever or too loose condition), is
the result of worn brakeshoes, improper brakeshoe BRAKE FLUID CONTAMINATION
adjustment, or improperly assembled brake parts. Indications of fluid contamination are swollen or
A “too loose” condition can also be caused by inop- deteriorated rubber parts.
erative or improperly assembled parking brakeshoe Swollen rubber parts indicate the presence of
parts. petroleum in the brake fluid.
A condition where the parking brakes do not hold, To test for contamination, put a small amount of
will most probably be due to a wheel brake compo- drained brake fluid in clear glass jar. If fluid sepa-
nent. rates into layers, there is mineral oil or other fluid
Items to look for when diagnosing a parking brake contamination of the brake fluid.
problem, are: If brake fluid is contaminated, drain and thor-
• Rear brakeshoe wear oughly flush system. Replace master cylinder, propor-
• Drum surface (in rear rotor) machined oversize tioning valve, caliper seals, wheel cylinder seals,
• Front cable not secured to lever Antilock Brakes hydraulic unit and all hydraulic
• Rear cable not attached to lever fluid hoses.
• Rear cable seized
• Parking shoes reversed
• Parking brake strut not seated in shoes SERVICE PROCEDURES
• Parking brake lever not seated
• Parking brake lever bind BRAKE FLUID LEVEL
• Cam and lever worn or misassembled Always clean the master cylinder reservoir and cap
• Adjuster screws seized before adding fluid. This will prevent dirt from fall-
• Adjuster screws reversed ing in the reservoir and contaminating the brake
Parking brake adjustment and parts replacement fluid.
procedures are described in the Parking Brake sec- The reservoir has a ADD and a FULL mark on the
tion. side (Fig. 13) fill to the FULL mark.

BRAKE LINE AND HOSES MASTER CYLINDER

Flexible rubber hose is used at both front brakes A new master cylinder should be bled before instal-
and at the rear axle junction block. Inspect the hoses lation on the vehicle. Required bleeding tools include
whenever the brake system is serviced, at every bleed tubes and a wood dowel to stroke the pistons.
engine oil change, or whenever the vehicle is in for Bleed tubes can be fabricated from brake line.
service.
Inspect the hoses for surface cracking, scuffing, or BLEEDING PROCEDURE
worn spots. Replace any brake hose immediately if (1) Mount master cylinder in vise.
the fabric casing of the hose is exposed due to cracks (2) Attach bleed tubes to cylinder outlet ports.
or abrasions. Then position each tube end in matching reservoir
Also check brake hose installation. Faulty installa- fluid compartment (Fig. 14).
tion can result in kinked, twisted hoses, or contact (3) Fill reservoir with fresh brake fluid.
with the wheels and tires or other chassis compo- (4) Press cylinder pistons inward with wood dowel.
nents. All of these condition can lead to scuffing, Then release pistons and allow them to return under
cracking and eventual failure.
5 - 12 BRAKES ZJ
SERVICE PROCEDURES (Continued)
MANUAL BLEEDING
(1) Remove reservoir filler caps and fill reservoir
with Mopar, or equivalent quality DOT 3 brake fluid.
(2) If calipers, or wheel cylinders were overhauled,
open all caliper and wheel cylinder bleed screws.
Then close each bleed screw as fluid starts to drip
from it. Top off master cylinder reservoir once more
before proceeding.
(3) Attach one end of bleed hose to bleed screw
and insert opposite end in glass container partially
filled with brake fluid (Fig. 15). Be sure end of bleed
hose is immersed in fluid.

Fig. 13 Master Cylinder Fluid Level

spring pressure. Continue bleeding operations until
air bubbles are no longer visible in fluid.

Fig. 15 Typical Fluid Container And Bleed Hose

Setup
Fig. 14 Master Cylinder Bleeding (4) Open up bleeder, then have a helper press
down the brake pedal. Once the pedal is down close
BRAKE BLEEDING the bleeder. Repeat bleeding until fluid stream is
Use Mopar brake fluid, or an equivalent quality clear and free of bubbles. Then move to the next
fluid meeting SAE J1703-F and DOT 3 standards wheel.
only. Use fresh, clean fluid from a sealed container at
all times. DISC ROTOR MACHINING
Do not pump the brake pedal at any time while Rotor braking surfaces can be sanded or machining
bleeding. Air in the system will be compressed into in a disc brake lathe.
small bubbles that are distributed throughout the The lathe must machine both sides of the rotor
hydraulic system. This will make additional bleeding simultaneously with dual (two) cutter heads (Fig.
operations necessary. 16). Equipment capable of machining only one side at
Do not allow the master cylinder to run out of fluid a time will produce a tapered rotor.
during bleed operations. An empty cylinder will allow The lathe should also be equipped with a grinder
additional air to be drawn into the system. Check the attachment or dual sanding discs for final cleanup or
cylinder fluid level frequently and add fluid as light refinishing (Fig. 16).
needed. If the rotor surfaces only need minor cleanup of
The Brakes should be bled in sequence. First the rust, scale, or minor scoring, use abrasive discs to
right rear wheel then the left rear wheel. Then move clean up the rotor surfaces. However, when a rotor is
to the front brakes and bleed the right front wheel scored or worn, machining with cutting tools will be
then the left front wheel. required.
ZJ BRAKES 5 - 13
SERVICE PROCEDURES (Continued)
CAUTION: Do not machine the rotor if it will cause line. Special bending tools are needed to avoid kink-
the rotor to fall below minimum allowable thick- ing or twisting metal brake line. In addition, special
ness. flaring tools are needed to provide the inverted-type,
double flare required on metal brake lines.

FLARING PROCEDURE
(1) Cut off damaged tube with Tubing Cutter.
(2) Ream cut edges of tubing to ensure proper
flare.
(3) Install replacement tube nut on section of tube
to be repaired.
(4) Insert tube in flaring tool. Center tube in area
between vertical posts.
(5) Place gauge form over the end of the tube.
(6) Push tubing through flaring tool jaws until
tube contacts recessed notch in gauge that matches
tube diameter.
(7) Squeeze flaring tool jaws to lock tubing in
place.
(8) Insert plug on gauge in the tube. Then swing
compression disc over gauge and center tapered flar-
ing screw in recess of compression disc (Fig. 17).
(9) Tighten tool handle until plug gauge is seated
on jaws of flaring tool. This will start the inverted
flare.
(10) Remove the plug gauge and complete the
inverted flare.
(11) Remove the flaring tools and verify that the
inverted flare is correct.

Fig. 16 Rotor Refinishing

BRAKE LINE
Mopar preformed metal brake line is recommended
Fig. 17 Inverted Flare Tools
and preferred for all repairs. However, double-wall
steel line can be used for emergency repair when fac-
tory replacement parts are not readily available.
Special, heavy duty tube bending and flaring
equipment is required to prepare double wall brake
5 - 14 BRAKES ZJ

REMOVAL AND INSTALLATION (5) Remove nut securing pedal shaft in support
bracket.
STOP LAMP SWITCH (6) Slide pedal shaft outward for clearance and
remove brake pedal.
REMOVAL (7) Remove pedal bushings if they are to be
(1) Remove steering column cover and lower trim replaced.
panel for switch access (if necessary).
(2) Press brake pedal downward to fully applied
position.
(3) Rotate switch approximately 30° in counter-
clockwise direction to unlock switch retainer. Then
pull switch rearward and out of bracket.
(4) Disconnect switch wire harness and remove
switch from vehicle (Fig. 18).

Fig. 19 Brake Pedal Mounting

INSTALLATION
Fig. 18 Stop Lamp Switch (1) Install new bushings in pedal. Lubricate bush-
INSTALLATION ings and pivot pin with Mopar multi-mileage grease.
(1) Pull switch plunger all the way out to fully (2) Position pedal, sleeve and spacer(s) in bracket
extended position. and install pedal shaft in support and through pedal.
(2) Connect harness wires to switch. (3) Install new nut on pedal shaft. Shaft nut is
(3) Press and hold brake pedal in applied position. specially formed and should not be reused. Be
(4) Install switch as follows: Align tab on switch sure to install new nut to secure shaft.
with notch in switch bracket. Then insert switch in (4) Tighten pedal shaft nut to 27 N·m (20 ft. lbs.)
bracket and turn it clockwise about 30° to lock it in on models with manual transmission. Tighten nut to
place. 35 N·m (26 ft. lbs.) on models with automatic trans-
(5) Release brake pedal. Then pull pedal fully rear- mission.
ward. Pedal will set plunger to correct position as (5) Install bushing on pedal pin if removed (Fig.
pedal pushes plunger into switch body. Switch will 19).
make racheting sound as it self adjusts. (6) Install booster push rod on pedal pin. Secure
push rod to pedal with retainer ring and washers.
BRAKE PEDAL (7) Install dash brace rod, if equipped.
(8) Install instrument panel trim and air condi-
REMOVAL tioning duct if removed.
(1) Remove lower trim panel and air conditioning (9) Check and adjust brakelight switch if neces-
duct if necessary. sary.
(2) Remove steering column lower trim panel and
bezel. COMBINATION VALVE
(3) Remove necessary dash panel-to-instrument
panel brace rods. REMOVAL
(4) Remove retainer clip and washers attaching (1) Remove brakelines that connect master cylin-
booster push rod to pedal pin (Fig. 19). der to combination valve (Fig. 20).
ZJ BRAKES 5 - 15
REMOVAL AND INSTALLATION (Continued)
(2) Disconnect brakelines that connect combination (6) Bleed brakes.
valve to HCU.
(3) Disconnect wire from combination valve switch MASTER CYLINDER
terminal. Be careful when separating wire connector
as lock tabs are easily damaged if not fully disen- REMOVAL
gaged. (1) Remove brakelines from master cylinder.
(4) Slide HCU solenoid harness connectors off com- (2) Remove combination valve.
bination valve bracket. Then move harness aside for (3) Remove nuts that attach master cylinder to
working clearance. booster studs (Fig. 22). Retain nuts as they are
(5) Remove nuts attaching combination valve special locking types.
bracket to booster studs and valve bracket off booster
studs (Fig. 21).

Fig. 22 Master Cylinder Mounting

(4) Remove master cylinder from booster.
Fig. 20 Combination Valve Brakelines INSTALLATION
(1) Remove protective cover from end of primary
piston.
(2) Bleed master cylinder.
(3) Slide master cylinder onto booster studs. Align
booster push rod in cylinder primary piston and seat
cylinder against booster.
(4) Install master cylinder mounting nuts and
tighten nuts to 25 N·m (220 in. lbs.). Use original
or factory replacement nuts only.
(5) Install combination valve and tighten mounting
nuts to 25 N·m (220 in. lbs.).
(6) Install brakelines that connect master cylinder
to combination valve.
(7) Fill and bleed brake system.

POWER BRAKE BOOSTER

Fig. 21 Combination Valve Bracket
REMOVAL
INSTALLATION
(1) Remove air filter housing,.
(1) Position valve bracket on booster studs and
(2) Remove master cylinder, combination valve,
tighten bracket attaching nuts to 25 N·m (220 in.
and HCU.
lbs.).
(3) Disconnect vacuum hose at booster check valve
(2) Align and start all four brakeline fittings in
(Fig. 23).
combination valve by hand to avoid cross threading.
(4) Remove retainer clip that booster push rod to
Then tighten fittings just enough to prevent leakage.
pedal pin (Fig. 24). Then slide push rod off pin.
(3) Connect wire to differential pressure switch in
(5) Remove four locknuts that attach booster to
combination valve.
dash panel.
(4) Tighten brakeline fittings at master cylinder
(6) In engine compartment, slide booster forward,
just enough to prevent leakage.
tilt it upward slightly, and remove it from engine
(5) Attach HCU solenoid harness connectors to
compartment.
combination valve bracket.
5 - 16 BRAKES ZJ
REMOVAL AND INSTALLATION (Continued)
(6) (b) Install booster attaching nuts on studs.
Tighten attaching nuts to 41 N·m (30 ft. lbs.).
(7) (c) Slide booster push rod on pedal pin. Then
secure rod to pin with retainer clip.
(8) (5) In engine compartment, attach vacuum
hose to booster check valve.
(9) (6) Install master cylinder, combination valve,
and HCU. Refer to procedures in this section.
(10) (7) Bleed brakes. Refer to section covering
brake bleeding.
(11) (8) Install engine air cleaner and hoses.

DISC BRAKE CALIPER

REMOVAL
(1) Raise vehicle and remove front wheel and tire
Fig. 23 Booster Check Valve And Hose assemblies.
(2) Remove and discard brake hose mounting bolt
(7) If booster will be stored on bench for any
(Fig. 25).
length of time, cover booster with shop towels to pre-
vent dust entry and place short lengths of rubber
hose over booster studs to protect threads.

Fig. 25 Brake Hose And Bolt

(3) Remove caliper mounting bolts.
Fig. 24 Power Brake Booster Mounting (4) Rotate caliper rearward with pry tool if neces-
sary. Then rotate caliper and brakeshoes off mount-
INSTALLATION
ing ledges.
(1) Check condition of grommet that secures check
(5) Remove caliper from vehicle.
valve in booster. Replace grommet if cut, torn, or
loose (no longer secures valve tightly). INSTALLATION
(2) Wipe booster mounting surface of dash panel (1) Install brakeshoes in caliper.
clean with shop towel. (2) Connect brake hose to caliper but do not
(3) Align and position booster on engine compart- tighten fitting bolt completely at this time. Be sure
ment side of dash panel. to use new gaskets on bolt to avoid leaks
(4) (4) Inside passenger compartment: (3) Install caliper. Position mounting notches at
(5) (a) Lubricate pedal pin and bushing with lower end of brakeshoes on bottom mounting ledge.
Mopar multi-mileage grease.
ZJ BRAKES 5 - 17
REMOVAL AND INSTALLATION (Continued)
Then rotate caliper over rotor and seat notches at (4) Remove caliper mounting bolts (Fig. 27).
upper end of shoes on mounting ledge.
(4) Coat caliper mounting bolts with GE 661 or
Dow 111 silicone grease. Then install and tighten
bolts to 10-20 N·m (7-15 ft. lbs.).

CAUTION: If new caliper bolts are being installed,

or if the original reason for repair was a drag/pull
condition, check caliper bolt length before proceed-
ing. If the bolts have a shank length greater than
67.6 mm (2.66 in.), they may contact the inboard
brakeshoe causing a partial apply condition. Refer
to Figure 14 for the required caliper bolt length.

(5) Position front brake hose clear of all chassis

components and tighten caliper fitting bolt to 31 N·m
(23 ft. lbs.).

CAUTION: Be sure the brake hose is not twisted or Fig. 27 Caliper Mounting Bolts
kinked at any point. Also be sure the hose is clear (5) Tilt top of caliper outward with pry tool if nec-
of all steering and suspension components. Loosen essary (Fig. 28) and remove caliper.
and reposition the hose if necessary.

(6) Install wheel and tire assembly.

(7) Fill master cylinder and bleed brake system.

DISC BRAKESHOE
REMOVAL
(1) Raise vehicle and remove front wheel and tire
assemblies.
(2) Drain small amount of fluid from master cylin-
der front brake reservoir with suction gun.
(3) Bottom caliper piston in bore with C-clamp.
Position clamp screw on outboard brakeshoe and
clamp frame on rear of caliper. Typical C-clamp
attachment is shown in (Fig. 26). Do not allow
clamp screw to bear directly on outboard shoe
Fig. 28 Caliper Removal
retainer spring. Use wood or metal spacer
between shoe and clamp screw if necessary. (6) Remove outboard shoe by pressing one end of
shoe inward to disengage shoe lug. Then rotate shoe
upward until retainer spring clears caliper. Press
opposite end of shoe inward to disengage shoe lug
and rotate shoe up and out of caliper (Fig. 29).
(7) Remove inboard shoe. Grasp ends of shoe and
tilt shoe outward to release springs from caliper pis-
ton (Fig. 30). Then remove shoe from caliper.

NOTE: If original brakeshoes will be used, keep

them in sets (left and right); they are not inter-
changeable.

(8) Secure caliper to nearby suspension part with

wire. Do not allow brake hose to support caliper
weight.
(9) Wipe caliper off with shop rags or towels. Do
not use compressed air. Compressed air can
Fig. 26 Bottoming Caliper Piston With C-Clamp
5 - 18 BRAKES ZJ
REMOVAL AND INSTALLATION (Continued)

Fig. 29 Outboard Brakeshoe Removal

Fig. 31 Caliper Lubrication Points

Fig. 30 Inboard Brakeshoe Removal

unseat dust boot and force dirt into piston
bore.

INSTALLATION
(1) Clean brakeshoe mounting ledge slide surfaces
of steering knuckle with wire brush. Then apply light
Fig. 32 Caliper Installation
coat of Mopar multi-mileage grease to slide surfaces.
Lubricate mounting bolts and bushings with GE 661 CAUTION: Before securing the caliper, be sure the
or Dow 111 silicone grease (Fig. 31). caliper brake hose is not twisted, kinked or touch-
(2) Install inboard shoe in caliper and verify shoe ing any chassis components.
retaining springs are fully seated into the piston.
(3) Install outboard shoe in caliper by starting one (5) Install and tighten caliper mounting bolts to
end of shoe in caliper and rotating shoe downward 10-20 N·m (7-15 ft. lbs.).
into place. Verify shoe locating lugs and shoe spring
CAUTION: If new caliper bolts are being installed,
are seated.
or if reason for repair was a drag/pull condition,
(4) Install caliper by position notches at lower end
check caliper bolt length. If the bolts have a shank
of brakeshoes on bottom mounting ledge. Then install
length greater than 67.6 mm (2.66 in.), they will con-
caliper over rotor and seat upper ends of brakeshoes
tact the inboard brakeshoe causing a partial apply
on top mounting ledge (Fig. 32).
condition. Refer to (Fig. 33) for correct caliper bolt
length.

(6) Install wheel and tire assemblies.

ZJ BRAKES 5 - 19
REMOVAL AND INSTALLATION (Continued)
REAR DISC BRAKE CALIPER
REMOVAL
(1) Raise vehicle and remove tire and wheel
assemblies.
(2) Press caliper piston into caliper bore with
C-clamp (Fig. 35).
(3) Remove caliper mounting bolts (Fig. 36).
(4) Rotate caliper rearward by hand or with pry
tool. Then rotate caliper and brakeshoes off ledges of
mounting bracket.
(5) Remove caliper fitting bolt and disconnect rear
brake hose at caliper. Discard metal washers on fit-
ting bolt. Washers should be replaced and not reused.
(6) Remove caliper from vehicle.

Fig. 33 Mounting Bolt Dimensions

(7) Pump brake pedal until caliper pistons and
brakeshoes are seated.
(8) Top off brake fluid level if necessary.

DISC BRAKE ROTOR

REMOVAL
(1) Remove wheel and tire assemble.
(2) Remove caliper.
(3) Remove retainers securing rotor to hub studs
(Fig. 34).
(4) Remove rotor from hub.
(5) If rotor shield requires service, remove front
hub and bearing assembly.
Fig. 35 Bottoming Caliper Piston

Fig. 34 Rotor & Hub

INSTALLATION Fig. 36 Caliper Mounting Bolt
(1) If new rotor is being installed, remove protec- INSTALLATION
tive coating from rotor surfaces with Mopar carb (1) Verify that brakeshoes are correctly positioned
cleaner. in caliper.
(2) Install rotor on hub. (2) Position caliper over rotor and into bracket. Be
(3) Install caliper. sure brakeshoe tabs are properly seated on mounting
(4) Install new spring nuts on wheel studs. bracket ledges.
(5) Install wheel and tire assembly.
5 - 20 BRAKES ZJ
REMOVAL AND INSTALLATION (Continued)
(3) Connect rear brake hose to caliper. Use new
washers on hose fitting and tighten hose fitting bolt
to 24-38 N·m (216-336 in. lbs.).
(4) Check brake hose position before proceeding.
Verify that hose is not twisted, kinked, or touching
any suspension components.

CAUTION: Check caliper bolt length before pro-

ceeding (Fig. 37). If the bolts have a shank length
greater than 67.6 mm (2.66 in.), they will contact the
inboard brakeshoe causing a partial apply condi-
tion.

Fig. 38 Rear Caliper

(8) Inspect caliper mounting bolt bushings and
boots. Replace boots if torn or cut. Replace bushings,
or bolts if either exhibits wear, or heavy corrosion.

INSTALLATION
(1) Clean brakeshoe contact surfaces of caliper
mounting bracket (Fig. 39). Use wire brush or emery
cloth.

Fig. 37 Caliper Mounting Bolt Dimensions

(5) Lubricate and install caliper mounting bolts.
Start bolts by hand then tighten bolts to 10-20 N·m
(7-15 ft. lbs.).
(6) Fill and bleed brake system.
(7) Install wheel and tire assemblies.
(8) Lower vehicle.

REAR DISC BRAKESHOES Fig. 39 Brakeshoe Contact Surfaces

REMOVAL (2) Install brakeshoes in caliper.

(1) Raise and support vehicle. (3) Install caliper over rotor and into mounting
(2) Remove rear wheel and tire assemblies. bracket.
(3) Press caliper piston back into caliper bore with (4) Verify that brakeshoe lugs are properly seated
large C-clamp. on caliper mounting bracket (Fig. 40). Be sure
(4) Remove caliper mounting bolts. springs on outboard shoes are also seated against
(5) Rotate caliper rearward and off rotor (Fig. 38). bracket.
Support caliper with wire attached to nearby suspen- (5) Verify hose must not be twisted or kinked.
sion component. Do not allow brake hose to sup- (6) Lubricate and install caliper mounting bolts
port caliper weight. and tighten to 10-20 N·m (7-15 ft. lbs.).
(6) Press one corner of outboard shoe inward then (7) Install wheel and tire assemblies.
pry shoe upward with suitable tool and rotate shoe (8) Turn ignition On and run HCU pump until it
out of caliper. shuts off. Then pump brake pedal until shoes are
(7) Pry inboard shoe outward until shoe retainers seated and indicator lights go out.
come out of caliper piston. Then remove shoe from (9) Top off brake fluid level if necessary. Use
caliper. Mopar brake fluid or equivalent meeting SAE J1703
and DOT 3 standards only.
ZJ BRAKES 5 - 21
REMOVAL AND INSTALLATION (Continued)

Fig. 40 Correct Brakeshoe Position Fig. 41 Backing Off Parking Brake Shoes
REAR DISC BRAKE ROTOR (7) Pump brake pedal to seat caliper piston and
brakeshoes. Do not move vehicle until firm brake
REMOVAL pedal is obtained.
(1) Raise vehicle.
(2) Remove wheel and tire assembly. PARKING BRAKE HAND LEVER
(3) Remove caliper.
(4) Remove access plug from splash shield and REMOVAL
back off parking brakeshoes by rotating adjuster (1) Release parking brakes.
screw star wheel with brake tool (Fig. 41). At driver (2) Disconnect battery negative cable.
side rear wheel, rotate adjuster screw star wheel (3) Raise vehicle on hoist.
clockwise to back off shoes. At passenger side wheel, (4) Remove front cable adjusting nut and disen-
rotate star wheel in counterclockwise direction. gage cable tensioner from equalizer. Then remove
Direction of rotation is while looking from rear to front cable from tensioner (Fig. 42).
front of vehicle. (5) Disengage front cable from insert and insert
(5) If rotor and/or axle hub contact surfaces are from floorpan.
heavily rusted, apply Mopar rust penetrant to rotor (6) Lower vehicle.
and axle hub and through spaces around wheel (7) Remove center console, refer to Group 23 Body.
studs. (8) Disconnect parking brake switch and air bag
(6) Remove push nuts securing rotor to axle shaft module wiring connectors.
studs. (9) Remove screws attaching air bag control mod-
(7) Work rotor off axle hub and studs. Use plastic ule to floorpan and parking brake lever. Then move
or rawhide mallet to loosen rotor if necessary. module aside for access to lever (Fig. 43).
(8) Clean and inspect rotor braking surfaces. (10) Remove screws attaching parking brake lever
Refinish, or replace rotor if necessary. to bracket and lift lever upward for access to front
cable (Fig. 42).
INSTALLATION (11) Disengage front cable from parking brake
(1) Clean axle hub and hub bore in rotor with wire lever and remove lever assembly from vehicle.
brush, or emery cloth.
(2) Install rotor on axle hub. INSTALLATION
(3) Install disc brake caliper. (1) Connect front cable to lever assembly.
(4) Install wheel and tire assembly and lower vehi- (2) Seat front cable in floor pan.
cle. (3) Install lever assembly on mounting bracket.
(5) Adjust parking brakeshoes. Use brake tool to (4) Connect parking brake switch wire.
rotate adjuster screw star wheel. Tighten shoes until (5) Install air bag control module and connect
light drag is created. Then back off shoes about 1/2 to module wires harnesses.
one turn of star wheel. (6) Install parking lever cover.
(6) Install plug in splash shield access hole. (7) Install center console, refer to Group 23 Body.
(8) Raise vehicle.
5 - 22 BRAKES ZJ
REMOVAL AND INSTALLATION (Continued)
(12) Connect battery negative cable.

FRONT PARKING BRAKE CABLE

REMOVAL
(1) Release parking brakes.
(2) Disconnect battery negative cable and raise
vehicle on hoist.
(3) Remove front cable adjusting nut and disen-
gage cable tensioner from equalizer. Then remove
front cable from tensioner (Fig. 44).
(4) Disengage front cable from insert and insert
from floorpan.
(5) Lower vehicle.
(6) Remove console, refer to Group 23 Body.
(7) Remove park brake lever.
(8) Disconnect front cable from parking brake
lever and remove cable.

Fig. 42 Parking Brake Lever And Cable Attachment

Fig. 44 Park Brake Cable Attachment

INSTALLATION
(1) Connect front cable to lever assembly.
(2) Seat front cable in floor pan.
(3) Install lever assembly.
(4) Install console.
(5) Raise vehicle.
(6) Assemble front cable, cable tensioner and
equalizer.
(7) Adjust parking brake system if new cable, or
tensioner has been installed, or if tensioner mecha-
nism has been loosened, or removed for access to
other components. Refer to Parking Brake Adjust-
ment procedure in this section.
(8) Lower vehicle.
(9) Connect battery negative cable.
Fig. 43 Air Bag Module Mounting
REAR PARKING BRAKE CABLE
(9) Assemble front cable, cable tensioner and cable
bracket. REMOVAL
(10) Adjust parking brake front cable. (1) Raise vehicle and loosen adjusting nut at
(11) Lower vehicle. equalizer to provide slack in rear cables.
ZJ BRAKES 5 - 23
REMOVAL AND INSTALLATION (Continued)
(2) Disengage cable at equalizer. Then disengage
cable from body and chassis clips and retainers.
(3) Slide cable eyelet off actuating lever (Fig. 45).
(4) Compress retainer securing cable in bracket
attached to caliper bracket. Then remove cable from
bracket.

Fig. 46 Retracting Parking Brake Shoes

Fig. 45 Rear Cable Attachment

INSTALLATION
(1) Install cable eyelet on lever. Be sure eyelet is
seated in lever notch.
(2) Seat cable retainer in caliper bracket.
(3) Route cable up to cable tensioner and equalizer.
Then connect cable to equalizer.
(4) Check cable routing. Be sure cable is secured
in body and chassis clips and retainers. Also be sure
cable is not twisted, kinked or touching any rotating
components.
(5) Adjust parking brake.

PARKING BRAKESHOES
REMOVAL
(1) Raise vehicle.
(2) Remove rear wheel and tire assembly.
(3) Remove caliper. Do not allow brake hose to
support caliper weight. Support caliper with
wire attached to suspension component.
(4) Remove rubber access plug from back of rear
disc brake splash shield.
(5) Retract parking brakeshoes with brake
Fig. 47 Holddown Clip And Pin
adjuster tool (Fig. 46). Position tool at top of star
wheel and rotate wheel downward in clockwise direc- (8) Remove upper and lower springs from shoes
tion (while facing front of vehicle). with needle nose pliers (Fig. 48).
(6) Remove rotor from axle hub flange. (9) Tilt shoes outward and remove adjuster screw.
(7) Remove shoe holddown clips and pins (Fig. 47). Note adjuster screw position for installation
Clip is held in place by pin which fits in clip notch. reference.
To remove clip, first push clip ends together with (10) Inspect condition of all brake components.
thumb or forefinger. Next, slide clip upward until Replace parts if bent, damaged or worn.
head of pin clears narrow part of notch. Then remove (11) Clean and inspect condition of adjuster screw
pin and clip. assembly. Replace assembly if worn, or damaged.
5 - 24 BRAKES ZJ
REMOVAL AND INSTALLATION (Continued)
PARKING BRAKE CAM AND LEVER
NOTE: The cams are reversible and can be used on
either wheel. The levers are NOT reversible. They
are marked R and L and the lever notch (for the
cable eyelet), must faces rearward on both sides.

REMOVAL
(1) Raise vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake caliper and rotor.
(4) Remove parking brakeshoes.
(5) Move lever forward and disconnect parking
brake rear cable from lever.
(6) Pull lever forward through boot. Disengage
Fig. 48 Lower Spring cam from lever and remove cam (Fig. 50). Note cam
position for installation reference.
INSTALLATION (7) Remove lever.
(1) Lubricate shoe contact pads and cam and lever
with Mopar multi-mileage grease (Fig. 49).

Fig. 50 Cam, Lever And Boot

INSTALLATION
(1) Lubricate replacement lever with silicone
grease. Then insert lever part way through boot. Be
sure lever notch is facing rearward.
Fig. 49 Shoe Contact Pads (2) Engage cam in lever. Then simultaneously slide
cam into place on splash shield and work lever
(2) Install shoes on splash shield with hold down through boot (Fig. 51).
clips and pins. Be sure shoes are properly engaged in (3) Install parking brakeshoes.
caliper bracket and cam. (4) Verify correct installation of cam and lever by
(3) Install adjuster screw assembly. Be sure pulling lever toward front of vehicle. Cam should
notched ends of screw assembly are properly seated expand both brakeshoes as lever is pulled forward.
on shoes and that star wheel is aligned with access (5) Install rotor and adjust parking brakeshoes.
hole in shield. (6) Connect rear cable to lever. Be sure cable eye-
(4) Install shoe upper and lower return spring. let is securely attached in lever notch.
Needle nose pliers can be used to connect spring to (7) Install brake caliper and wheel and tire assem-
each shoe. Operate lever to verify that shoes expand bly.
and retract properly. (8) Lower vehicle and verify correct parking brake
(5) Install rotor and caliper. operation.
(6) Adjust parking brakeshoes.
(7) Install wheel and tire assembly. SPLASH SHIELD/CALIPER BRACKET/LEVER BOOT
(8) Adjust parking brake cable tensioner.
(9) Lower vehicle and verify correct parking brake REMOVAL
operation. (1) Raise vehicle and remove wheel and tire
assembly.
ZJ BRAKES 5 - 25
REMOVAL AND INSTALLATION (Continued)
(10) Note position of cam and lever for installation
reference. Then remove cam and lever from splash
shield and bracket.
(11) Separate splash shield and caliper bracket.
Then remove lever boot from bracket (Fig. 53).

Fig. 51 Cam And Lever

(2) Remove caliper bolts and lift caliper off rotor
and bracket. Suspend caliper from chassis or suspen-
sion component with wire.
(3) Retract parking brakeshoes and remove rotor.
(4) Remove axle shaft. Refer to Group 3 for proce-
dure.
(5) Remove parking brakeshoes from splash shield.
(6) Remove nuts attaching splash shield and cali-
per bracket to axle tube flange.
(7) Remove splash shield and caliper bracket from
axle studs and work lever out of rear cable eyelet. Fig. 53 Caliper Bracket, Splash Shield And Lever
(8) Mark position of splash shield and bracket for Boot
assembly reference. Use paint or scriber to mark INSTALLATION
parts. (1) If original bracket and shield will be reused,
(9) Drill out rivets that retain splash shield to cal- clean them with Mopar carb and brake cleaner. Also
iper bracket (Fig. 52). If rivet heads did not come clean shoe contact pad surfaces of shield with 400
completely off after drilling, remove remaining pieces grit paper. Lubricate pad surfaces with light coat of
with small chisel. Note that the rivets do not Mopar multi-mileage grease.
have to be replaced at installation. The rivets (2) Apply thin coat of contact cement or silicone
are only used during manufacture to keep the adhesive to new lever boot and to boot mounting area
boot in place during handling. of caliper bracket (Fig. 54). Apply adhesive to areas
where boot and bracket contact one another. Adhe-
sive is needed to hold boot in position when splash
shield is attached to bracket.

Fig. 54 Applying Adhesive To Parking Brake Lever

Boot
(3) Install new boot on caliper bracket. Metal
Fig. 52 Drilling Out Splash Shield Rivets retainer part of boot fits over ledge on caliper as shown
5 - 26 BRAKES ZJ
REMOVAL AND INSTALLATION (Continued)
(Fig. 55). Rubber part of boot extends through rear (7) Install parking brakeshoes on splash shield.
opening in bracket. Allow adhesive on boot and bracket Verify positioning of cam and lever, shoes, springs
to set up for a minute or two before proceeding. and holddown clips and pins (Fig. 57).

Fig. 55 Lever Boot Installation

(4) Position splash shield on caliper bracket. Then
carefully install shield and bracket assembly on axle
tube flange studs.

CAUTION: Be sure the parking brake lever boot is not

displaced when the shield/assembly is installed. If the Fig. 57 Parking Brakeshoes Mounted On Shield
boot becomes mispositioned, it will prevent the shield (8) Verify correct positioning of caliper bracket and
from seating squarely on the bracket. This will cock the shield (Fig. 58). Caliper opening and ledges should be
shield causing it to rub against the rotor after installa- to rear as shown.
tion. Inspect the boot and reposition it if necessary.

(5) Apply Mopar Lock N’ Seal (or Loctite 242), to

axle tube stud nuts. Then install and tighten nuts to
43-61 N·m (32-45 ft. lbs.).
(6) Assemble and install cam and lever. Push lever
through boot and seat cam between lip on shield and
ledge on bracket (Fig. 56). Then engage lever in cable
eyelet. Be sure cable notch in lever is facing rearward.
Remove and reposition cam and lever if necessary.

Fig. 58 Checking Caliper Bracket And Shield

Position
(9) Install axle shaft, shaft retainer clips and hous-
ing cover. Check lube level and add lubricant if
needed.
(10) Install rotor, caliper, and wheel and tire
assembly. Then adjust parking brakeshoes.
(11) Lower vehicle and verify correct service and
parking brake operation.

Fig. 56 Cam And Lever Installation

ZJ BRAKES 5 - 27

DISASSEMBLY AND ASSEMBLY (5) Remove reservoir by rocking it to one side and
pulling free of grommets (Fig. 61).
MASTER CYLINDER RESERVOIR
REMOVAL
(1) Remove reservoir cap and empty fluid into
drain container.
(2) Remove pins that retain reservoir to master
cylinder. Use hammer and pin punch to remove pins
(Fig. 59).

Fig. 61 Reservoir Removal

(6) Remove old grommets from cylinder body (Fig. 62).

Fig. 59 Reservoir Retaining Pins

(3) Clamp cylinder body in vise with brass protec- Fig. 62 Grommet Removal
tive jaws. INSTALLATION
(4) Loosen reservoir from grommets with pry tool
(Fig. 60). CAUTION: Do not use any type of tool to install
the grommets. Tools may cut, or tear the grommets
creating a leak problem after installation. Install the
grommets using finger pressure only.

(1) Lubricate new grommets with clean brake fluid

and Install new grommets in cylinder body (Fig. 63).
Use finger pressure to install and seat grommets.

Fig. 60 Loosening Reservoir

Fig. 63 Grommet Installation

5 - 28 BRAKES ZJ
DISASSEMBLY AND ASSEMBLY (Continued)
(2) Start reservoir in grommets. Then rock reser-
voir back and forth while pressing downward to seat
it in grommets.
(3) Install pins that retain reservoir to cylinder body.
(4) Fill and bleed master cylinder on bench before
installation in vehicle.

DISC BRAKE CALIPER

DISASSEMBLY
(1) Remove brakeshoes from caliper.
(2) Drain brake fluid out of caliper.
(3) Pad interior of caliper with minimum, 2.54 cm (1
in.) thickness of shop towels or rags (Fig. 64). Towels
are needed to protect caliper piston during removal.

Fig. 65 Caliper Piston Removal

Fig. 64 Padding Caliper Interior

(4) Remove caliper piston with short bursts of
low pressure compressed air. Direct air through fluid
inlet port and ease piston out of bore (Fig. 65).

CAUTION: Do not blow the piston out of the bore

with sustained air pressure. This could result in a
cracked piston. Use only enough air pressure to
ease the piston out. NEVER attempt to catch the Fig. 66 Caliper Piston Dust Boot Removal
piston as it leaves the bore. This will result in per-
sonal injury.

(5) Remove caliper piston dust boot with suitable

tool (Fig. 66) and discard boot.
(6) Remove caliper piston seal with wood or plastic
tool (Fig. 67) and discard seal. Do not use metal tools
as they will scratch piston bore.
(7) Remove caliper mounting bolt bushings and
boots (Fig. 68).

ASSEMBLY
(1) Coat caliper piston bore, new piston seal and
piston with clean brake fluid.
(2) Lubricate caliper bushings and interior of
bushing boots with Dielectric silicone grease.
Fig. 67 Piston Seal Removal
ZJ BRAKES 5 - 29
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 68 Mounting Bolt Bushing And Boot

Fig. 71 Dust Boot On Piston
(3) Install bushing boots in caliper, then insert
bushing into boot and push bushing into place (Fig.
69).

Fig. 72 Caliper Piston Installation

(7) Press caliper piston to bottom of bore.
Fig. 69 Bushings And Boots Installation (8) Seat dust boot in caliper with Installer Tool
(4) Install new piston seal into seal groove with C-4842 and Tool Handle C-4171 (Fig. 73).
finger (Fig. 70).

Fig. 70 Piston Seal Installation

(5) Install dust boot on caliper piston and seat boot
in piston groove (Fig. 71).
(6) Press piston into caliper bore by hand, use a
turn and push motion to work piston into seal (Fig.
72). Fig. 73 Piston Dust Boot Installation
5 - 30 BRAKES ZJ
DISASSEMBLY AND ASSEMBLY (Continued)
(9) Replace caliper bleed screw if removed.

REAR DISC BRAKE CALIPER

DISASSEMBLY
(1) Remove caliper and brakeshoes.
(2) Remove mounting bolt boots and bushings from
caliper (Fig. 74).

Fig. 76 Caliper Piston Removal

Fig. 74 Mounting Bolt Bushings And Boots

(3) Pad interior of caliper with minimum, one-inch
thickness of shop towels or rags (Fig. 75). Towels are
needed to protect caliper piston during removal.

Fig. 77 Caliper Piston Dust Boot

Fig. 75 Padding Caliper

(4) Remove caliper piston with short bursts of
low pressure compressed air. Direct air through fluid
inlet port and ease piston out of bore (Fig. 76).

CAUTION: Do not blow the piston out of the bore

with sustained air pressure. This could result in a
cracked piston. Use only enough air pressure to
ease the piston out. In addition, NEVER attempt to
catch the piston as it leaves the bore. This could
result in personal injury.

(5) Remove caliper piston dust boot (Fig. 77).

(6) Remove and discard caliper piston seal with
pencil, or plastic tool (Fig. 78). Do not use metal tools
as they will scratch piston bore.
Fig. 78 Caliper Piston Seal
ASSEMBLY (2) Install new piston seal in groove machined in
(1) Lubricate caliper piston bore and new piston piston bore. Be sure seal is fully seated and is not
seal with clean brake fluid. twisted. Press seal into place with fingertips.
ZJ BRAKES 5 - 31
DISASSEMBLY AND ASSEMBLY (Continued)
(3) Lubricate caliper piston with clean brake fluid (9) Install bushing and boot assemblies in caliper.
and start piston into bore and seal by hand. Use a Be sure boots are centered in caliper as shown.
twisting, rocking motion to start piston into seal. (10) Apply GE or Dow silicone grease to interior of
Keep piston level while starting it in seal other- bushing boots. Then apply same lubricant to exterior
wise seal can be folded over. and interior of bushings.
(4) Once piston is firmly started in seal, press pis- (11) Install mounting bolt bushings in boots (Fig.
ton about 2/3 of way into bore with C-clamp or bench 81). Be sure boot lips are seated in grooves at ends of
vise (Fig. 79). bushings.
(12) Center bushing boots in caliper.
CAUTION: Position a protective wood block
between the piston and C-clamp or vise jaws. The
wood block will avoid chipping or cracking the pis-
ton while pressing it into place.

Fig. 81 Bushings Installed In Boots

(13) Install brakeshoes in caliper.
(14) Install caliper.

CLEANING AND INSPECTION

CALIPER
Fig. 79 Piston Installed In Caliper
CLEANING
(5) Install dust boot on piston. Be sure boot lip is
Clean the caliper components with clean brake
fully seated in groove at top of caliper piston.
fluid or Mopar brake cleaning solvent only. Do not
(6) Seat dust boot in caliper either by hand, or
use gasoline, kerosene, thinner, or similar solvents.
with a suitable size installer tool (Fig. 80).
These products may leave a residue that could dam-
age the piston and seal.
Wipe the caliper and piston dry with lint free tow-
els or use low pressure compressed air.

INSPECTION
The piston is made from a phenolic resin (plastic
material) and should be smooth and clean.
Replace the piston if cracked or scored. Do not
attempt to restore a scored piston surface by sanding
or polishing. The piston must be replaced if damaged.

NOTE: If the caliper piston must be replaced,

install the same type of piston in the caliper. Never
interchange phenolic resin and steel caliper pis-
tons. The pistons, seals, seal grooves, caliper bore
and piston tolerances are different for resin and
Fig. 80 Seating Caliper Piston Dust Boot steel pistons. Do not intermix these components at
any time.
(7) Press caliper to bottom of bore after seating
dust boot. Be sure to use wood block to protect piston The bore can be lightly polished with a brake hone
and boot. to remove very minor surface imperfections (Fig. 82).
(8) Install caliper bleed screw, if removed. The caliper should be replaced if the bore is severely
5 - 32 BRAKES ZJ
CLEANING AND INSPECTION (Continued)
corroded, rusted, scored, or if polishing would (7) Lower vehicle enough for access to parking
increase bore diameter more than 0.025 mm (0.001 brake lever. Then fully apply parking brakes. Leave
inch). brakes applied until adjustment is complete.
(8) Raise vehicle and mark tensioner rod 6.5 mm
(1/4 in.) from tensioner bracket (Fig. 83).
(9) Tighten adjusting nut at equalizer until mark
on tensioner rod moves into alignment with tensioner
bracket.
(10) Lower vehicle until rear wheels are 15-20 cm
(6-8 in.) off shop floor.
(11) Release parking brake lever and verify that
rear wheels rotate freely without drag.
(12) Lower vehicle.

NOTE: Do not loosen/tighten equalizer adjusting

nut for any reason after completing adjustment.

Fig. 82 Lightly Polishing Piston Bore With Tool

ADJUSTMENTS
STOP LAMP SWITCH
(1) Press and hold brake pedal in applied position.
(2) Pull switch plunger all the way out to fully
extended position.
(3) Release brake pedal. Then pull pedal fully rear-
ward. Pedal will set plunger to correct position as
pedal pushes plunger into switch body. Switch will
make racheting sound as it self adjusts.

PARKING BRAKE CABLE TENSIONER

NOTE: Parking brake adjustment is only necessary Fig. 83 Tensioner Rod Measurement
when the tensioner, or a cable has been replaced or PARKING BRAKESHOE
disconnected for service. When adjustment is nec- (1) Remove wheel and tire assemblies.
essary, perform the following procedure for proper (2) Secure rotor with two wheel nuts.
parking brake operation. (3) Remove rubber access plug from back of splash
shield.
ADJUSTMENT (4) Insert brake tool through access hole in splash
(1) Raise vehicle. shield (Fig. 84). Position tool at bottom of star wheel.
(2) Back off tensioner adjusting nut to create slack (5) Rotate star wheel upward in counterclockwise
in cables. direction to expand shoes (while facing front of vehi-
(3) Remove rear wheel/tire assemblies and remove cle).
brake drums. (6) Expand shoes until light drag is experienced.
(4) Check rear brakeshoe adjustment with stan- Then back off adjuster screw only enough to elimi-
dard brake gauge. Excessive shoe-to-drum clear- nate drag.
ance, or worn brake components will result in (7) Install plug in splash shield access hole.
faulty parking brake adjustment and operation. (8) Install wheel and tire assemblies.
(5) Verify that parking brake cables operate freely
and are not binding, or seized. Replace faulty cables, SPECIFICATIONS
before proceeding.
(6) Reinstall brake drums and wheel/tire assem- BRAKE FLUID
blies after brakeshoe adjustment is complete. The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
ZJ BRAKES 5 - 33
SPECIFICATIONS (Continued)
TORQUE CHART

DESCRIPTION TORQUE
Brake Pedal
Support Bolt . . . . . . . . . .23-34 N·m (17-25 ft. lbs.)
Pivot Bolt/Nut . . . . . . . . .27-35 N·m (20-26 ft. lbs.)
Brake Booster
Mounting Nuts . . . . . . . . . . . . .41 N·m (30 ft. lbs.)
Master Cylinder
Mounting Nuts . . . . . . . .13-25 N·m (10-18 ft. lbs.)
Primary Brakeline . . . . . .15-18 N·m (11-13 ft. lbs.)
Secondary Brakeline . . . .15-18 N·m (11-13 ft. lbs.)
Combination Valve
Mounting Nuts . . . . . . . . . . . .25 N·m (18.5 ft. lbs.)
Brakeline to Master Cyl. .15-18 N·m (11-13 ft. lbs.)
Fig. 84 Park Brakeshoe Adjustment Front Caliper
Mounting Bolts . . . . . . . . .10-20 N·m (7-15 ft. lbs.)
approved for usage in the vehicle brake system. Use
Brake Hose Bolt . . . . . . . . . . . .31 N·m (23 ft. lbs.)
only Mopar brake fluid or an equivalent from a
Rear Caliper
tightly sealed container.
Mounting Bolts . . . . . . . . .10-20 N·m (7-15 ft. lbs.)
CAUTION: Never use reclaimed brake fluid or fluid Brake Hose Bolt . . . . . . . . . . . .31 N·m (23 ft. lbs.)
from an container which has been left open. An Parking Brake
open container will absorb moisture from the air Lever Screws . . . . . . . . . . .10-14 N·m (7-10 ft. lbs.)
and contaminate the fluid. Lever Bracket Screws . . . .10-14 N·m (7-10 ft. lbs.)
Cable Retainer Nut. . . . . . .1-2 N·m (12-16 in. lbs.)

CAUTION: Never use any type of a petroleum-

SPECIAL TOOLS
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
BASE BRAKES
vehicle brake hydraulic system causing a failure of
the vehicle brake system.

BRAKE COMPONENTS

Front Disc Brake Caliper

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Floating
Front Disc Brake Rotor
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ventilated
Max. Runout. . . . . . . . . . . . . . .0.13 mm (0.005 in.) Installer Caliper Dust Boot C-4842
Max. Thickness Variation . . .0.013mm (0.0005 in.)
Rear Disc Brake Caliper
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Floating
Rear Disc Brake Rotor
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Solid
Max. Runout. . . . . . . . . . . . . . .0.13 mm (0.005 in.)
Max. Thickness Variation . . .0.0254 mm (0.001 in.)
Brake Booster
Type . . . . . . . . . . . . . . . . . . . . . . .Dual Diaphragm

Handle C-4171
5 - 34 BRAKES ZJ

ANTILOCK BRAKES

INDEX
page page

GENERAL INFORMATION SERVICE PROCEDURES

ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 BLEEDING ABS BRAKE SYSTEM . . . . . . . . . . . 38
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION
ABS SYSTEM RELAYS . . . . . . . . . . . . . . . . . . . . 38 ACCELERATION SWITCH . . . . . . . . . . . . . . . . . 42
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . . 38 CONTROLLER ANTILOCK BRAKES . . . . . . . . . . 38
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 FRONT WHEEL SPEED SENSOR . . . . . . . . . . . 41
ACCELERATION SWITCH . . . . . . . . . . . . . . . . . 37 HYDRAULIC CONTROLLER UNIT . . . . . . . . . . . 39
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . 37 REAR WHEEL SPEED SENSOR . . . . . . . . . . . . 42
CONTROLLER ANTILOCK BRAKES (CAB) . . . . . 35 SPECIFICATIONS
HYDRAULIC CONTROL UNIT (HCU) . . . . . . . . . 35 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 43
WHEEL SPEED SENSORS AND TONE WHEEL . 37
DIAGNOSIS AND TESTING
ABS BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . 38

GENERAL INFORMATION
ABS
The antilock brake system (ABS) is an electroni-
cally operated, all wheel brake control system.
The system is designed to prevent wheel lockup
and maintain steering control during periods of high
wheel slip when braking. Preventing lockup is accom-
plished by modulating fluid pressure to the wheel
brake units.
The hydraulic system is a three channel design.
The front wheel brakes are controlled individually
and the rear wheel brakes in tandem (Fig. 1). The
ABS electrical system is separate from other electri-
cal circuits in the vehicle. A specially programmed
controller antilock brake unit (CAB) operates the sys-
tem components.
ABS system major components include:
• Controller Antilock Brakes (CAB)
• Hydraulic Control Unit (HCU)
• Wheel Speed Sensors (WSS)
• Acceleration Switch
• Main Relay And Pump Motor Relay Fig. 1 Jeep ABS System
• ABS Warning Light static and dynamic self check of system electrical
• Pump Motor Sensor components.
The static check occurs after the ignition switch is
DESCRIPTION AND OPERATION turned to Run position. The dynamic check occurs
when vehicle road speed reaches approximately 10
ABS kph (6 mph). During the dynamic check, the CAB
Battery voltage is supplied to the CAB ignition ter- briefly cycles the pump and solenoids to verify oper-
minal when the ignition switch is turned to Run posi- ation.
tion. The CAB performs a system initialization If an ABS component exhibits a fault during ini-
procedure at this point. Initialization consists of a tialization, the CAB illuminates the amber warning
ZJ BRAKES 5 - 35
DESCRIPTION AND OPERATION (Continued)
light and registers a fault code in the microprocessor els, it at the right side of the steering column. In
memory. right hand drive models, it is near the cowl panel
The CAB contains dual microprocessors. A logic
NORMAL BRAKING block in each microprocessor receives identical sensor
The CAB monitors wheel speed sensor inputs con- signals. These signals are processed and compared
tinuously while the vehicle is in motion. However, simultaneously.
the CAB will not activate any ABS components as The CAB contains a self check program that illu-
long as sensor inputs and the acceleration switch minates the ABS warning light when a system fault
indicate normal braking. is detected. Faults are stored in a diagnostic program
During normal braking, the master cylinder, power memory and are accessible with the DRB scan tool.
booster and wheel brake units all function as they ABS faults remain in memory until cleared, or
would in a vehicle without ABS. The HCU compo- until after the vehicle is started approximately 50
nents are not activated. times. Stored faults are not erased if the battery is
disconnected.
ANTILOCK BRAKING
The purpose of the antilock system is to prevent
wheel lockup during periods of high wheel slip. Pre-
venting lockup helps maintain vehicle braking action
and steering control.
The antilock CAB activates the system whenever
sensor signals indicate periods of high wheel slip.
High wheel slip can be described as the point where
wheel rotation begins approaching zero (or lockup)
during braking. Periods of high wheel slip occur
when brake stops involve high pedal pressure and
rate of vehicle deceleration.
The antilock system prevents lockup during high
slip conditions by modulating fluid apply pressure to
the wheel brake units.
Brake fluid apply pressure is modulated according
to wheel speed, degree of slip and rate of decelera-
tion. A sensor at each wheel converts wheel speed
into electrical signals. These signals are transmitted
to the CAB for processing and determination of
wheel slip and deceleration rate.
The ABS system has three fluid pressure control
channels. The front brakes are controlled separately
and the rear brakes in tandem. A speed sensor input
signal indicating a high slip condition activates the
CAB antilock program.
Two solenoid valves are used in each antilock con-
trol channel. The valves are all located within the
HCU valve body and work in pairs to either increase,
hold, or decrease apply pressure as needed in the Fig. 2 Controller Antilock Brakes
individual control channels. HYDRAULIC CONTROL UNIT (HCU)
The solenoid valves are not static during antilock The hydraulic control unit (HCU) consists of a
braking. They are cycled continuously to modulate valve body, pump body, accumulators, pump motor,
pressure. Solenoid cycle time in antilock mode can be and wire harnesses (Fig. 3).
measured in milliseconds. The pump, motor, and accumulators are combined
into an assembly attached to the valve body. The
CONTROLLER ANTILOCK BRAKES (CAB) accumulators store the extra fluid released to the
A separate electronic control unit (CAB) operates system for ABS mode operation. The pump provides
the ABS system (Fig. 2). The CAB is separate from the fluid volume needed and is operated by a DC
other vehicle electrical circuits. CAB voltage source is type motor. The motor is controlled by the CAB.
through the ignition switch in the RUN position. The valve body contains the solenoid valves. The
The CAB is located under the instrument panel in valves modulate brake pressure during antilock brak-
the passenger compartment. In left hand drive mod- ing and are controlled by the CAB.
5 - 36 BRAKES ZJ
DESCRIPTION AND OPERATION (Continued)
The HCU provides three channel pressure control
to the front and rear brakes. One channel controls
the rear wheel brakes in tandem. The two remaining
channels control the front wheel brakes individually.
During antilock braking, the solenoid valves are
opened and closed as needed. The valves are not
static. They are cycled rapidly and continuously to
modulate pressure and control wheel slip and decel-
eration.

Fig. 4 Pressure Decrease Cycle

Fig. 3 ABS Master Cylinder-Booster-Combination

Valve-HCU
During normal braking, the HCU solenoid valves
and pump are not activated. The master cylinder and
power booster operate the same as a vehicle without
an ABS brake system.
During antilock braking, solenoid valve pressure
modulation occurs in three stages, pressure increase,
pressure hold, and pressure decrease. The valves are
all contained in the valve body portion of the HCU.
Pressure Decrease
The outlet valve is opened and the inlet valve is
closed during the pressure decrease cycle (Fig. 4).
A pressure decrease cycle is initiated when speed
sensor signals indicate high wheel slip at one or
more wheels. At this point, the CAB opens the outlet
valve, which also opens the return circuit to the accu-
mulators. Fluid pressure is allowed to bleed off
(decrease) as needed to prevent wheel lock. Fig. 5 Pressure Hold Cycle
Once the period of high wheel slip has ended, the
The inlet valve is open and the outlet valve is
CAB closes the outlet valve and begins a pressure
closed during the pressure increase cycle (Fig. 6). The
increase or hold cycle as needed.
pressure increase cycle is used to counteract unequal
Pressure Hold
wheel speeds. This cycle controls re-application of
Both solenoid valves are closed in the pressure
fluid apply pressure due to changing road surfaces or
hold cycle (Fig. 5). Fluid apply pressure in the control
wheel speed.
channel is maintained at a constant rate. The CAB
maintains the hold cycle until sensor inputs indicate
a pressure change is necessary.
Pressure Increase
ZJ BRAKES 5 - 37
DESCRIPTION AND OPERATION (Continued)

Fig. 7 Wheel Speed Sensors

sensors have an air gap spacer attached to the sensor
pickup face. The spacer establishes correct air gap
when pressed against the tone ring during installa-
tion. As the tone ring rotates, it peels the spacer off
the sensor to create the required air gap. Rear sensor
Fig. 6 Pressure Increase Cycle air gap is 0.92-1.45 mm (0.036-0.057 in.).
WHEEL SPEED SENSORS AND TONE WHEEL Sensor air gap measurement, or adjustment proce-
A speed sensor is used at each wheel. The front dures are provided in this section. Refer to the front,
sensors are mounted to the steering knuckles. The or rear sensor removal and installation procedures as
rear sensors at the outboard end of the axle. required.
The sensors convert wheel speed into a small AC
electrical signal. This signal is transmitted to the COMBINATION VALVE
CAB. The CAB convert the AC signal into a digital The combination valve contains a pressure differ-
signal for each wheel. This voltage is generated by ential valve and switch and a rear brake proportion-
magnetic induction when a tone wheel passes by the ing valve. The valve is not repairable. It must be
stationary magnetic of the wheel speed sensor. replaced if diagnosis indicates this is necessary.
A gear type tone ring serves as the trigger mecha- The pressure differential switch is connected to the
nism for each sensor. The tone rings are mounted at brake warning light. The switch is actuated by move-
the outboard ends of the front and rear axle shafts. ment of the switch valve. The switch monitors fluid
Different sensors are used at the front and rear pressure in the separate front/rear brake hydraulic
wheels (Fig. 7). The front/rear sensors have the same circuits.
electrical values but are not interchangeable. The A decrease or loss of fluid pressure in either
sensors have a resistance between 900 and 1300 hydraulic circuit will cause the switch valve to shut-
ohms. tle to the low pressure side. Movement of the valve
pushes the switch plunger upward. This action closes
SPEED SENSOR AIR GAP the switch internal contacts completing the electrical
circuit to the red warning light. The switch valve will
Front Sensor remain in an actuated position until repairs are
Front sensor air gap is fixed and not adjustable. made.
Only rear sensor air gap is adjustable. The rear proportioning valve is used to balance
Although front air gap is not adjustable, it can be front-rear brake action. The valve allows normal
checked if diagnosis indicates this is necessary. Front fluid flow during moderate effort brake stops. The
air gap should be 0.40 to 1.3 mm (0.0157 to 0.051 valve only controls (meters) fluid flow during high
in.). If gap is incorrect, the sensor is either loose, or effort brake stops.
damaged.
ACCELERATION SWITCH
Rear Sensor The acceleration switch is located under the rear
A rear sensor air gap adjustment is only needed seat.
when reinstalling an original sensor. Replacement
5 - 38 BRAKES ZJ
DESCRIPTION AND OPERATION (Continued)
The switch (Fig. 8), provides an additional vehicle An ABS circuit fault is indicated when the amber
deceleration reference during 4-wheel drive opera- lamp remains on after startup, or illuminates at any
tion. The switch is monitored by the CAB at all time during vehicle operation.
times. The switch reference signal is utilized by the Verify that a fault is actually related to the ABS
CAB when all wheels are decelerating at the same system before making repairs. For example, if the
speed. red lamp illuminates but the amber ABS lamp does
not, the problem is related to a service brake compo-
nent and not the ABS system. Or, if neither lamp
illuminates but a brake problem is noted, again, the
problem is with a service brake component and not
with the ABS system.

DRB SCAN TOOL

ABS diagnosis is performed with the DRB scan
tool. Diagnosis information is provided in the Chassis
Diagnostic Manual.

ABS DIAGNOSTIC CONNECTOR

The ABS diagnostic connector is located inside the
vehicle. The connector is the access point for the
DRB scan tool.
The connector is blue or black in color and is a
6-way type. The connector is under the carpet at the
Fig. 8 Acceleration Switch forward end of the console just under the IP center.
ABS SYSTEM RELAYS
The ABS system has two relays, which are the SERVICE PROCEDURES
main and motor pump relays. The main relay is used
for the solenoid valves and CAB. The main relay is BLEEDING ABS BRAKE SYSTEM
connected to the CAB at the power control relay ter- ABS system bleeding requires conventional bleed-
minal. The motor pump relay is used for the motor ing methods plus use of the DRB scan tool. The pro-
pump only. The pump motor relay starts/stops the cedure involves performing a base brake bleeding,
pump motor when signaled by the CAB. followed by use of the scan tool to cycle and bleed the
HCU pump and solenoids. A second base brake bleed-
ABS WARNING LAMP ing procedure is then required to remove any air
The amber ABS warning lamp is located in the remaining in the system.
instrument cluster. The lamp illuminates at start-up (1) Perform base brake bleeding. Refer to base
to perform a self check. The lamp goes out when the brake section for procedure.
self check program determines the system is operat- (2) Connect scan tool to ABS diagnostic connector
ing normal. If an ABS component exhibits a fault the under carpet at front of console, just under instru-
CAB will illuminate the lamp and register a trouble ment panel center bezel.
code in the microprocessor. The lamp is controlled by (3) Select CHASSIS SYSTEM, followed by TEVES
the CAB and or the main relay through an in-har- ABS BRAKES, then BLEED BRAKES. When scan
ness diode. The CAB controls the lamp by directly tool displays TEST COMPLETE, disconnect scan tool
grounding the circuit. The main relay grounds the and proceed.
lamp circuit when it is de-energized. (4) Perform base brake bleeding a second time.
Refer to base brake section for procedure.
(5) Top off master cylinder fluid level and verify
DIAGNOSIS AND TESTING
proper brake operation before moving vehicle.
ABS BRAKE SYSTEM
REMOVAL AND INSTALLATION
ABS WARNING LAMP DISPLAY
The amber antilock lamp illuminates at startup as CONTROLLER ANTILOCK BRAKES
part of the system self check feature. The lamp illu-
minates for 1-3 seconds then goes off as part of the REMOVAL
normal bulb check routine. (1) Remove harness connectors from controller.
ZJ BRAKES 5 - 39
REMOVAL AND INSTALLATION (Continued)
(2) Remove mounting nut and remove controller
(Fig. 9).

Fig. 10 HCU Solenoid Harness Connector

Fig. 9 Controller Antilock Brakes

INSTALLATION
(1) Install controller on mounting stud.
(2) Install mounting nut and tighten to 6 N·m (55
in. lbs.). Fig. 11 HCU Bracket Mounting Nuts
(3) Connect harness connectors to controller.

HYDRAULIC CONTROLLER UNIT

REMOVAL
(1) Remove air filter housing.
(2) Slide HCU solenoid harness connector off
retaining tab on combination valve. Then unplug con-
nector from engine compartment harness and move it
aside (Fig. 10).
(3) Remove combination valve.
(4) Remove master cylinder.
(5) Remove mounting nuts from HCU bracket to
suspension support panel (Fig. 11). Retain bracket
nuts.
(6) Disconnect HCU pump motor harness (Fig. 12).
(7) Disconnect three brakelines at rear of HCU
(Fig. 13).
Fig. 12 HCU Pump Motor Harness Connector
(8) If HCU is to be replaced, remove flex lines (9) Lift HCU and bracket off mounting studs and
from HCU. remove assembly from engine compartment (Fig. 14).
5 - 40 BRAKES ZJ
REMOVAL AND INSTALLATION (Continued)

Fig. 15 HCU Bracket Bolts

Fig. 13 HCU Brakeline Connections

Fig. 16 HCU Bracket Isolators And Sleeves

(2) Position stud plate on underside of panel and
secure it with new retaining nuts (Fig. 17).

Fig. 14 HCU And Bracket

(10) Remove mounting bolts attaching mounting
bracket to HCU (Fig. 15).
(11) Separate bracket from HCU (Fig. 16). Note
that special shoulder bolts are used to attach
bracket to HCU. If bolts are damaged, do not
use substitute bolts. Use factory replacement
bolts only.
(12) Inspect rubber isolators and sleeves in HCU
bracket. Replace any washers or isolators if missing,
or damaged with factory replacement parts only. Do
not use substitute fasteners.

INSTALLATION
(1) Transfer mounting bracket to new HCU. Use
original shoulder style bolts to attach bracket to
HCU; do not use substitute fasteners. Fig. 17 Stud Plate And HCU Bracket
ZJ BRAKES 5 - 41
REMOVAL AND INSTALLATION (Continued)
(3) Install HCU bracket on mounting studs and
tighten bracket mounting nuts to 10-13 N·m (92-112
in. lbs.).
(4) Start brakeline fittings into ports at rear of
HCU. Start fittings by hand to avoid cross
threading. Then tighten fittings to 14-16 N·m (125-
140 in. lbs.).
(5) Install the master cylinder on booster and
tighten mounting nuts to 25 N·m (220 in. lbs.). Cyl-
inder attaching nuts are special and have an
interference fit thread. Do not use substitute
fasteners at any time.
(6) Install combination valve and tighten nuts to
25 N·m (220 in. lbs.).
(7) Install brakelines from HCU to combination
valve and tighten to 16 N·m (145 in. lbs.).
(8) Install master cylinder-to-combination valve Fig. 19 Sensor Wire Routing
brakelines and tighten to 16 N·m (145 in. lbs.).
(9) Connect HCU solenoid and pump motor wire
harnesses.
(10) Connect wire to combination valve switch.
(11) Fill and bleed brake system.
(12) Install air filter housing.

FRONT WHEEL SPEED SENSOR

REMOVAL
(1) Turn ignition switch to OFF position.
(2) Raise vehicle.
(3) Remove wheel and tire assembly.
(4) Remove bolt attaching front sensor to steering
knuckle (Fig. 18).

Fig. 20 Sensor Wire Grommet

(8) Remove sensor and wire assembly.

INSTALLATION
(1) Apply Mopar Lock N’ Seal or Loctite 242 to
sensor attaching bolt. Use new sensor bolt if original
bolt is worn or damaged.
(2) Position sensor on steering knuckle. Seat sen-
sor locating tab in hole in knuckle and install sensor
attaching bolt finger tight.
(3) Tighten sensor bolt to 14 N·m (11 ft. lbs.).
(4) Route sensor wire from steering knuckle to
fender panel.
(5) Engage grommets on sensor wire in brackets
Fig. 18 Sensor Location on body, chassis, frame, and steering knuckle.
(6) Check sensor wire routing. Be sure wire is
(5) Disengage sensor wire from brackets on steer- clear of all chassis components and is not twisted or
ing knuckle and frame member (Fig. 19) and (Fig. kinked at any spot.
20). (7) Seat sensor wire in body grommet and seat
(6) Unseat grommet that secures sensor wire in grommet in fender panel.
fender panel. (8) Connect sensor wire to harness in engine com-
(7) In engine compartment, disconnect sensor wire partment.
connector at harness plug.
5 - 42 BRAKES ZJ
REMOVAL AND INSTALLATION (Continued)
REAR WHEEL SPEED SENSOR spacer from sensor pickup face. Set air gap to 0.92-
1.45 mm (0.036-0.057 in.) with feeler gauge (Fig. 23).
REMOVAL Tighten sensor bolt to 14 N·m (11 ft. lbs.).
(1) Raise and fold rear seat forward. Then move (5) If new sensor is being installed, push card-
carpeting aside for access to rear sensor connectors. board spacer on sensor face (Fig. 24) against tone
(2) Disconnect rear sensor wires at harness con- ring. Then tighten sensor bolt to 14 N·m (11 ft. lbs.).
nectors. Correct air gap will be established as tone ring
(3) Push sensor wires and grommets through floor- rotates and peels spacer off sensor face.
pan holes. (6) Route sensor wires to rear seat area.
(4) Raise vehicle. (7) Feed sensor wires through floorpan access hole
(5) Remove wheel and brake drum. and seat sensor grommets in floorpan.
(6) Disengage sensor wire from axle and chassis (8) Secure sensor wire in brackets and in retainers
brackets and from brakeline retainers (Fig. 21). on rear brakelines. Verify that sensor wire is secure
(7) Unseat sensor grommet from brake support and clear of rotating components.
plate. (9) Install brake drum and wheel and lower vehi-
(8) Remove bolt attaching sensor to support plate cle.
bracket (Fig. 22). (10) Fold rear seat and carpet forward for access
(9) Remove sensor and wire through opening in to sensor wires and connectors.
support plate. (11) Connect sensor wires to harness connectors.
(12) Reposition carpet and fold rear seat down.

Fig. 21 Sensor Wire Attachment

Fig. 23 Setting Air Gap On Original Rear Sensor

Fig. 22 Sensor Mounting

INSTALLATION
(1) Insert sensor wire through support plate hole.
Then seat sensor wire grommet in hole to secure
wire.
(2) Apply Mopar Lock N’ Seal or Loctite 242 to Fig. 24 New Rear Sensor With Air Gap Spacer
original sensor bolt. Use new bolt if original is worn ACCELERATION SWITCH
or damaged.
(3) Install sensor bolt finger tight only at this REMOVAL
time. (1) Turn ignition switch to OFF position.
(4) If original sensor is being installed or (2) Disconnect battery negative cable.
adjusted, remove any remaining pieces of cardboard
ZJ BRAKES 5 - 43
REMOVAL AND INSTALLATION (Continued)

Fig. 25 Acceleration Sensor Mounting

(3) Tilt rear seat assembly forward for access to SPECIFICATIONS
sensor.
(4) Disconnect sensor harness (Fig. 25). TORQUE CHART
(5) Remove screws attaching sensor to bracket.
(6) Remove sensor. DESCRIPTION TORQUE
Acceleration Sensor
INSTALLATION
Sensor Bolt . . . . . . . . . . . . .8-9 N·m (71-83 in. lbs.)
CAUTION: The mercury switch (inside the acceler- Bracket Bolt . . . . . . . . . . . .1-2 N·m (13-18 in. lbs.)
ation switch), will not function properly if the switch Hydraulic Control Unit
is mispositioned. Verify that the locating arrow is Mounting Nuts . . . . . . .10-13 N·m (92-112 in. lbs.)
pointing to the front of the vehicle. Brakelines . . . . . . . . . .14-16 N·m (125-140 in. lbs.)
Controller Anitlock Brakes
(1) Note position of locating arrow on switch. Posi- Mounting Bolts . . . . . . . .8-13 N·m (75-115 in. lbs.)
tion switch so arrow faces forward. Wheel Speed Sensors
(2) Position switch in mounting bracket. Front Mounting Bolt. . . . . . . . . .4-6 (34-50 in. lbs.)
(3) Install and tighten switch attaching screws to Rear Mounting Bolt. . .12-14 N·m (106-124 in. lbs.)
2-4 N·m (17-32 in. lbs.).
(4) Connect harness to switch. Be sure harness
connector is firmly seated.
(5) Move rear seat back to normal position.
(6) Connect battery negative cable.