brake system JEEP LIBERTY 2002 KJ / 1.G User Guide

INSTALLATION
INSTALLATION - FRONT BRAKE HOSE
(1) Install the hose.
(2) Install the mounting bolt for the top of the
brake hose at the vehicle (Fig. 8).(3) Install the brake hose banjo bolt at the caliper.
(4) Lower the vehicle and remove the support.
(5) Install the brake line to the brake hose inside
the engine compartment by the front control arm
bolt.
(6) Remove the prop rod from the brake pedal.
(7) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
INSTALLATION - REAR BRAKE HOSE
(1) Install the hose.
(2) Install the mounting bolt for the brake hose at
the axle (Fig. 7).
(3) Install the two brake lines at the bottom of the
hose located at the axle (Fig. 7).
(4) Install the vent tube (Fig. 7).
(5) Install the brake hose mounting bolt at the top
of the hose located at the body (Fig. 6).
(6) Install the brake line to the hose at the body
(Fig. 6).
(7) Lower the vehicle and remove the support.
(8) Remove the prop rod.
(9) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
BRAKE PADS / SHOES
DESCRIPTION - REAR DRUM BRAKE
The rear brakes use a leading shoe (primary) and
trailing shoe (secondary) design (Right rear brake is
shown) (Fig. 9).
Fig. 6 BRAKE HOSE AT THE BODY
1 - MOUNTING BOLT
2 - BRAKE HOSE
3 - BRAKE LINE
4 - COIL SPRING
Fig. 7 BRAKE HOSE AT THE AXLE
1 - REAR WHEEL SPEED SENSOR
2 - BRAKE HOSE
3 - VENT HOSE
4 - BRAKE LINES
5 - MOUNTING BOLT
Fig. 8 BRAKE HOSE MOUNTED
1 - COIL SPRING
2 - MOUNTING BOLT
3 - BRAKE HOSE
4 - FRONT OF THE UPPER CONTROL ARM
5 - 10 BRAKES - BASEKJ
BRAKE LINES (Continued)

OPERATION
When the brakes are applied fluid pressure is
exerted against the caliper piston. The fluid pressure
is exerted equally and in all directions. This means
pressure exerted against the caliper piston and
within the caliper bore will be equal (Fig. 14).
Fluid pressure applied to the piston is transmitted
directly to the inboard brake shoe. This forces the
shoe lining against the inner surface of the disc
brake rotor. At the same time, fluid pressure within
the piston bore forces the caliper to slide inward on
the mounting bolts. This action brings the outboard
brake shoe lining into contact with the outer surface
of the disc brake rotor.
In summary, fluid pressure acting simultaneously
on both piston and caliper, produces a strong clamp-
ing action. When sufficient force is applied, friction
will attempt to stop the rotors from turning and
bring the vehicle to a stop.
Application and release of the brake pedal gener-
ates only a very slight movement of the caliper and
piston. Upon release of the pedal, the caliper and pis-
ton return to a rest position. The brake shoes do not
retract an appreciable distance from the rotor. In
fact, clearance is usually at, or close to zero. The rea-
sons for this are to keep road debris from gettingbetween the rotor and lining and in wiping the rotor
surface clear each revolution.
The caliper piston seal controls the amount of pis-
ton extension needed to compensate for normal lining
wear.
During brake application, the seal is deflected out-
ward by fluid pressure and piston movement (Fig.
15). When the brakes (and fluid pressure) are
released, the seal relaxes and retracts the piston.
The amount of piston retraction is determined by
the amount of seal deflection. Generally the amount
is just enough to maintain contact between the pis-
ton and inboard brake shoe.
REMOVAL
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support vehicle.
(3) Remove front wheel and tire assembly.
(4) Drain small amount of fluid from master cylin-
der brake reservoir with suction gun.
(5) Remove the brake hose banjo bolt if replacing
caliper (Fig. 16).
(6) Remove the caliper mounting slide pin bolts
(Fig. 16).
(7) Remove the caliper from vehicle.
DISASSEMBLY
(1) Remove brake shoes from caliper.
(2) Drain brake fluid out of caliper.
(3) Take a piece of wood and pad it with one-inch
thickness of shop towels. Place this piece in the out-
board shoe side of the caliper in front of the piston.
This will cushion and protect caliper piston during
removal (Fig. 17).
Fig. 14 Brake Caliper Operation
1 - CALIPER
2 - PISTON
3 - PISTON BORE
4 - SEAL
5 - INBOARD SHOE
6 - OUTBOARD SHOE
Fig. 15 Lining Wear Compensation By Piston Seal
1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON
5 - 14 BRAKES - BASEKJ
DISC BRAKE CALIPERS (Continued)

(4) Install the brake hose to the caliper withnew
seal washersand tighten fitting bolt to 31 N´m (23
ft. lbs.).
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(5) Remove the prop rod from the vehicle.
(6) Bleed the base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE) OR (Refer to
5 - BRAKES - STANDARD PROCEDURE).
(7) Install the wheel and tire assemblies (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(8) Remove the supports and lower the vehicle.
(9) Verify a firm pedal before moving the vehicle.
DISC BRAKE CALIPER
ADAPTER
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front wheel and tire assembly.
(3) Drain a small amount of fluid from master cyl-
inder brake reservoir with acleansuction gun.
(4) Bottom the caliper pistons into the caliper by
prying the caliper over.
(5) Remove the caliper mounting bolts (Fig. 16).
(6) Remove the disc brake caliper from the mount.
CAUTION: Never allow the disc brake caliper to
hang from the brake hose. Damage to the brake
hose will result. Provide a suitable support to hang
the caliper securely.
(7) Remove the inboard and outboard brake pads.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - REMOVAL).
(8) Remove the caliper adapter mounting bolts
(Fig. 16).
INSTALLATION
(1) Install the caliper adapter mounting bolts.
Tighten the mounting bolts to 135 N´m (100 ft.lbs).
(2) Install the inboard and outboard pads. (Refer
to 5 - BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - INSTALLATION).
(3) Install the caliper mounting bolts.
(4) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
ROTORS
DIAGNOSIS AND TESTING - DISC BRAKE
ROTOR
The rotor braking surfaces should not be refinished
unless necessary.
Light surface rust and scale can be removed with a
lathe equipped with dual sanding discs. The rotor
surfaces can be restored by machining in a disc brake
lathe if surface scoring and wear are light.
Replace the rotor under the following conditions:
²severely scored
²tapered
²hard spots
²cracked
²below minimum thickness
ROTOR MINIMUM THICKNESS
Measure rotor thickness at the center of the brake
shoe contact surface. Replace the rotor if worn below
minimum thickness, or if machining would reduce
thickness below the allowable minimum.
Rotor minimum thickness is usually specified on
the rotor hub. The specification is either stamped or
cast into the hub surface.
ROTOR RUNOUT
Check rotor lateral runout with dial indicator
C-3339 (Fig. 28). Excessive lateral runout will cause
brake pedal pulsation and rapid, uneven wear of the
brake shoes. Position the dial indicator plunger
approximately 25.4 mm (1 in.) inward from the rotor
edge. The dial indicator should be positioned in the
center of the rotor surface. Maximum allowable rotor
runout is 0.102 mm (0.004 in.).
ROTOR THICKNESS VARIATION
Variations in rotor thickness will cause pedal pul-
sation, noise and shudder.
Measure rotor thickness at 6 to 12 points around
the rotor face (Fig. 29).
Position the micrometer approximately 25.4 mm (1
in.) from the rotor outer circumference for each mea-
surement.
Thickness should notvaryby more than 0.013 mm
(0.0005 in.) from point-to-point on the rotor. Machine
or replace the rotor if necessary.
5 - 18 BRAKES - BASEKJ
DISC BRAKE CALIPERS (Continued)

JUNCTION BLOCK
DESCRIPTION
The junction block and a rear brake proportioning
valve. The valve is not repairable and must be
replaced as an assembly if diagnosis indicates this is
necessary.
OPERATION
PROPORTIONING VALVE
The proportioning valve is used to balance front-
rear brake action at high decelerations. The valve
allows normal fluid flow during moderate braking.
The valve only controls fluid flow during high decel-
erations brake stops. If the primary brake hydraulic
circuit cannot build pressure a by-pass feature is
activated allowing full flow and pressure to the rear
brakes.
DIAGNOSIS AND TESTING - PROPORTIONING
VALVE
The valve controls fluid flow. If fluid enters the
valve and does not exit the valve the combination
valve must be replaced.
REMOVAL
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove the brake lines from the junction
block.
(3) Remove mounting nuts and bolt and remove
the junction block (Fig. 31).
INSTALLATION
(1) Install the junction block on the mounting
studs.
(2) Install mounting nuts and bolt. Tighten to 14
N´m (125 in. lbs.).
(3) Install brake lines to the junction block and
tighten to 20 N´m (180 in. lbs.).
(4) Bleed ABS brake system (Refer to 5 - BRAKES
- STANDARD PROCEDURE).
PEDAL
DESCRIPTION
A suspended-type brake pedal is used, the pedal
pivots on a shaft mounted in the steering coloumn
support bracket. The bracket is attached to the dash
panel. The unit is serviced as an assembly, except for
the pedal pad.
OPERATION
The brake pedal is attached to the booster push
rod. When the pedal is depressed, the primary
booster push rod is depressed which move the booster
secondary rod. The booster secondary rod depress the
master cylinder piston.
REMOVAL
(1) Remove the knee blocker under the steering
column,(Refer to 23 - BODY/INSTRUMENT PANEL/
KNEE BLOCKER - REMOVAL).
(2) Remove the retainer clip securing the booster
push rod to pedal (Fig. 32).
(3) Remove the brake lamp switch,(Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).
(4) Remove the nuts securing the pedal to the col-
umn bracket.
(5) Remove the pedal from the vehicle.
INSTALLATION
(1) Install the pedal into the vehicle.
(2) Install the nuts securing the pedal to the col-
umn bracket.
(3) Tighten the nuts to 22.6 N´m (200 in. lbs.).
(4) Lubricate the brake pedal pin and bushings
with Mopar multi-mileage grease.
(5) Install the booster push rod on the pedal pin
and install a new retainer clip (Fig. 32).
(6) Install the brake lamp switch,(Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION).
(7) Install the knee blocker,(Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL-
LATION).
Fig. 31 JUNCTION BLOCK
1 - JUNCTION BLOCK
2 - MOUNTING NUT
5 - 20 BRAKES - BASEKJ

(4) Tighten booster mounting nuts to 22.6 N´m
(200 ft. lbs.).
(5) Install the knee blocker,(Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL-
LATION).
(6) If original master cylinder is being installed,
check condition of seal at rear of master cylinder.
Replace seal if cut, or torn.
(7) Clean cylinder mounting surface of brake
booster. Use shop towel wetted with brake cleaner for
this purpose. Dirt, grease, or similar materials will
prevent proper cylinder seating and could result in
vacuum leak.
(8) Align and install master cylinder on the
booster studs. Install mounting nuts and tighten to
22.6 N´m (200 in. lbs.).
(9) Connect vacuum hose to booster check valve.
(10) Remount the HCU. Tighten bracket mounting
nuts to 22.6 N´m (200 in. lbs.).
(11) Connect and secure the brake lines to HCU or
junction block and master cylinder. Start all brake
line fittings by hand to avoid cross threading.
(12) Connect the wire to fluid level switch at the
bottom of the reservoir.
(13) Fill and bleed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
(14) Verify proper brake operation before moving
vehicle.
MASTER CYLINDER
DESCRIPTION
The master cylinder has a removable nylon reser-
voir. The cylinder body is made of aluminum and
contains a primary and secondary piston assembly.
The cylinder body including the piston assemblies
are not serviceable. If diagnosis indicates an internal
problem with the cylinder body, it must be replaced
as an assembly. The reservoir and grommets are the
only replaceable parts on the master cylinder.
OPERATION
The master cylinder bore contains a primary and
secondary piston. The primary piston supplies
hydraulic pressure to the front brakes. The secondary
piston supplies hydraulic pressure to the rear brakes.
The master cylinder reservoir stores reserve brake
fluid for the hydraulic brake circuits.
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER
(1) Start engine and check booster vacuum hose
connections. A hissing noise indicates vacuum leak.
Correct any vacuum leak before proceeding.(2) Stop engine and shift transmission into Neu-
tral.
(3) Pump brake pedal until all vacuum reserve in
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
fall away slightly under light foot pressure then hold
firm. If no pedal action is discernible, power booster,
vacuum supply, or vacuum check valve is faulty. Pro-
ceed 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 turn off igni-
tion to stop engine.
(7) Wait a minimum of 90 seconds and try brake
action again. Booster should provide two or more vac-
uum assisted pedal applications. If vacuum assist is
not provided, booster is faulty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check valve
with short length of hose and T-fitting (Fig. 38).
(2) Start and run engine at curb idle speed for one
minute.
(3) Observe the vacuum supply. If vacuum supply
is not adequate, repair vacuum supply.
(4) Clamp hose shut between vacuum source and
check valve.
(5) Stop engine and observe vacuum gauge.
(6) If vacuum drops more than one inch HG (33
millibars) within 15 seconds, booster diaphragm or
check valve is faulty.
POWER BOOSTER CHECK VALVE TEST
(1) Disconnect vacuum hose from check valve.
(2) Remove check valve and valve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Apply 15-20 inches vacuum at large end of
check valve (Fig. 39).
(5) Vacuum should hold steady. If gauge on pump
indicates vacuum loss, check valve is faulty and
should be replaced.
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
A new master cylinder should be bled before instal-
lation on the vehicle. Required bleeding tools include
bleed tubes and a wood dowel to stroke the pistons.
Bleed tubes can be fabricated from brake line.
(1) Mount master cylinder in vise.
5 - 24 BRAKES - BASEKJ
POWER BRAKE BOOSTER (Continued)

(2) Attach bleed tubes to cylinder outlet ports.
Then position each tube end into reservoir (Fig. 40).
(3) Fill reservoir with fresh brake fluid.
(4) Press cylinder pistons inward with wood dowel.
Then release pistons and allow them to return underspring pressure. Continue bleeding operations until
air bubbles are no longer visible in fluid.
REMOVAL
(1) Siphon and drain the fluid from the reservoir.
(2) Remove the brake lines at the master cylinder.
(3) Disconnect the fluid level electrical connector
from the reservoir.
(4) Remove mounting nuts from the master cylin-
der.
(5) Remove master cylinder.
(6) Remove cylinder cover and drain the rest of the
fluid.
(7) If master cylinder reservoir requires service-
,(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
FLUID RESERVOIR - REMOVAL). (Fig. 41)
INSTALLATION
NOTE: If master cylinder is replaced, bleed cylinder
before installation.
(1) Clean cylinder mounting surface of brake
booster.
(2) Install master cylinder onto brake booster
studs.
(3) Install mounting nuts and tighten to 25 N´m
(220 in. lbs.).
(4) Connect the brake lines to the master cylinder
and tighten to 20 N´m (180 in. lbs.).
(5) Connect fluid level electrical connector to the
reservoir.
(6) Fill and bleed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
Fig. 38 Typical Booster Vacuum Test Connections
1 - TEE FITTING
2 - SHORT CONNECTING HOSE
3 - CHECK VALVE
4 - CHECK VALVE HOSE
5 - CLAMP TOOL
6 - INTAKE MANIFOLD
7 - VACUUM GAUGE
Fig. 39 TYPICAL - VACUUM CHECK VALVE AND
SEAL
1 - BOOSTER CHECK VALVE
2 - APPLY TEST VACUUM HERE
3 - VALVE SEAL
Fig. 40 MASTER - TYPICAL
1 - BLEEDING TUBES
2 - RESERVOIR
KJBRAKES - BASE 5 - 25
MASTER CYLINDER (Continued)

FLUID RESERVOIR
REMOVAL
(1) Install prop rod on brake pedal to keep pres-
sure on the brake system.
(2) Remove reservoir cap and siphon fluid into
drain container.
(3) Remove the electrical connector from the fluid
level switch in the reservoir.
(4) Remove the reservoir mounting bolt.
(5) Remove the reservoir from the master cylinder
by pulling upwards.
(6) Remove old grommets from cylinder body.
INSTALLATION
(1) Fill and bleed master cylinder on bench before
installation in vehicle.
CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(2) Lubricate new grommets with clean brake fluid
and Install new grommets in cylinder body. Use fin-
ger pressure to install and seat grommets.
(3) Start reservoir in grommets. Then rock reser-
voir back and forth while pressing downward to seat
it in grommets.
(4) Install the mounting bolt for the reservoir to
the master cylinder.
(5) Reconnect the electrical connector to the fluid
reservoir level switch.(6) Remove the prop rod from the vehicle.
(7) Fill and bleed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brakes hydraulic unit and all hydraulic
fluid hoses.
STANDARD PROCEDURES - MASTER
CYLINDER FLUID LEVEL
Always clean the master cylinder reservoir and cap
before adding fluid. This will prevent dirt from fall-
ing in the reservoir and contaminating the brake
fluid.
The reservoir has a ADD and a FULL mark on the
side (Fig. 42) fill to the FULL mark.
Fig. 41 MASTER CYLINDER
1 - FLUID RESERVOIR
2 - BOOSTER
3 - FLUID LEVEL SWITCH
4 - MASTER CYLINDER
5 - FLUID LEVEL MARKS
Fig. 42 TYPICAL - MASTER CYLINDER FLUID
LEVEL
1 - FLUID LEVEL MARKS
2 - RESERVOIR
5 - 26 BRAKES - BASEKJ
MASTER CYLINDER (Continued)

SPECIFICATIONS
BRAKE FLUID
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
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
DRUM
DIAGNOSIS AND TESTING - BRAKE DRUM
The maximum allowable diameter of the drum
braking surface is indicated on the drum outer edge.
Generally, a drum can be machined to a maximum of
1.52 mm (0.060 in.) oversize. Always replace the
drum if machining would cause drum diameter to
exceed the size limit indicated on the drum.
BRAKE DRUM RUNOUT
Measure drum diameter and runout with an accu-
rate gauge. The most accurate method of measure-
ment involves mounting the drum in a brake lathe
and checking variation and runout with a dial indi-
cator.
Variations in drum diameter should not exceed
0.076 mm (0.003 in.). Drum runout should not exceed
0.20 mm (0.008 in.) out of round. Machine the drum
if runout or variation exceed these values. Replace
the drum if machining causes the drum to exceed the
maximum allowable diameter.
STANDARD PROCEDURES - BRAKE DRUM
MACHINING
The brake drums can be machined on a drum lathe
when necessary. Initial machining cuts should be lim-
ited to 0.12 - 0.20 mm (0.005 - 0.008 in.) at a time as
heavier feed rates can produce taper and surface
variation. Final finish cuts of 0.025 to 0.038 mm(0.001 to 0.0015 in.) are recommended and will gen-
erally provide the best surface finish.
Be sure the drum is securely mounted in the lathe
before machining operations. A damper strap should
always be used around the drum to reduce vibration
and avoid chatter marks.
The maximum allowable diameter of the drum
braking surface is stamped or cast into the drum
outer edge.
CAUTION: Replace the drum if machining will cause
the drum to exceed the maximum allowable diame-
ter.
SUPPORT PLATE
REMOVAL
REMOVAL - 198 RBI AXLE
(1) Remove wheel and tire assembly.
(2) Remove the brake drum.
(3) Remove the brake shoes.
(4) Remove parking brake cable from parking
brake lever.
(5) Compress parking brake cable retainer tabs.
Then push retainer and cable through and out of
support plate.
(6) Disconnect brake line at wheel cylinder.
(7) Remove wheel cylinder from support plate,(Re-
fer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
WHEEL CYLINDERS - REMOVAL).
(8) Remove the four bolts attaching the support
plate to axle and remove the support plate with the
axle, bearing and seal.
(9) Remove axle shaft,(Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/REAR AXLE/AXLE SHAFTS -
REMOVAL).
REMOVAL - 8 1/4 AXLE
(1) Remove the wheel and tire assembly.
(2) Remove the brake drum.
(3) Install the brake pedal prop rod.
(4) Remove the brake shoes (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- REMOVAL).
(5) Remove parking brake cable from parking
brake lever.
(6) Compress parking brake cable retainer tabs.
Then push retainer and cable through and out of
support plate.
(7) Disconnect the brake line at wheel cylinder.
(8) Remove the wheel cylinder from the support
plate,(Refer to 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/WHEEL CYLINDERS - REMOVAL).
KJBRAKES - BASE 5 - 27
FLUID (Continued)

(9) Remove the axle shaft, (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/REAR AXLE - 8 1/4/AXLE
SHAFTS - REMOVAL).
(10) Remove the bolts attaching the support plate
to the axle and remove the support plate (Fig. 43).
INSTALLATION
INSTALLATION - 198 RBI AXLE
(1) Install the support plate on the axle flange.
Tighten 75 N´m (55 ft. lbs.)
(2) Install the axle, bearing and seal into the hous-
ing and tighten the four attaching bolts to 61 N´m
(45 ft. lbs.).
(3) Install the wheel cylinder,(Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/WHEEL
CYLINDERS - INSTALLATION).
(4) Install the brake line in the wheel cylinder.
(5) Install the parking brake cable in the support
plate.
(6) Connect parking brake cable to lever on sec-
ondary shoe and install brake shoes on support plate.
(7) Adjust the brake shoes to the drum with the
brake gauge.
(8) Install the brake drum and wheel and tire
assembly (Refer to 22 - TIRES/WHEELS/WHEELS -
STANDARD PROCEDURE).
(9) Bleed brake system,(Refer to 5 - BRAKES -
STANDARD PROCEDURE) OR (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
INSTALLATION - 8 1/4 AXLE
(1) Install the support plate on the axle flange.
Tighten attaching bolts to 61 N´m (45 ft. lbs.) (Fig.
43).(2) Install the wheel cylinder,(Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/WHEEL
CYLINDERS - INSTALLATION).
(3) Install the brake line in the wheel cylinder and
tighten the line to 14 N´m (124 in.lbs.)..
(4) Remove the brake pedal prop rod.
(5) Install the parking brake cable in the support
plate.
(6) Install the axle shaft, (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/REAR AXLE - 8 1/4/AXLE
SHAFTS - INSTALLATION).
(7) Connect the parking brake cable to the lever on
the primary shoe and install the brake shoes on the
support plate (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/BRAKE PADS/SHOES - INSTALLA-
TION).
(8) Adjust the brake shoes to the drum with the
brake gauge (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/BRAKE PADS/SHOES - ADJUST-
MENTS).
(9) Install the brake drum.
(10) Install the wheel and tire assembly (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(11) Bleed the brake system,(Refer to 5 - BRAKES
- STANDARD PROCEDURE).
WHEEL CYLINDERS
REMOVAL
(1) Remove wheel and tire assembly.
(2) Remove brake drum.
(3) Install brake pedal prop rod.
(4) Disconnect wheel cylinder brake line.
(5) Remove brake shoe return springs and move
shoes out of engagement with cylinder push rods.
(6) Remove cylinder attaching bolts and remove
cylinder from support plate (Fig. 44).
DISASSEMBLY
(1) Remove push rods and boots (Fig. 45).
(2) Press pistons, cups and spring and expander
out of cylinder bore.
(3) Remove bleed screw.
CLEANING
Clean the cylinder and pistons with clean brake
fluid or brake cleaner only. Do not use any other
cleaning agents.
Dry the cylinder and pistons with compressed air.
Do not use rags or shop towels to dry the cylinder
components. Lint from cloth material will adhere to
the cylinder bores and pistons.
Fig. 43 SUPPORT PLATE 8 1/4
1 - SUPPORT PLATE
2 - MOUNTING NUTS
5 - 28 BRAKES - BASEKJ
SUPPORT PLATE (Continued)

INSPECTION
Inspect the cylinder bore. Light discoloration and
dark stains in the bore are normal and will not
impair cylinder operation.
The cylinder bore can be lightly polished but only
with crocus cloth. Replace the cylinder if the bore is
scored, pitted or heavily corroded. Honing the bore to
restore the surface is not recommended.
Inspect the cylinder pistons. The piston surfaces
should be smooth and free of scratches, scoring and
corrosion. Replace the pistons if worn, scored, or cor-
roded. Do not attempt to restore the surface by sand-
ing or polishing.Discard the old piston cups and the spring and
expander. These parts are not reusable. The original
dust boots may be reused but only if they are in good
condition.
ASSEMBLY
(1) Lubricate wheel cylinder bore, pistons, piston
cups and spring and expander with clean brake fluid.
(2) Install first piston in cylinder bore. Then
install first cup in bore and against piston.Be sure
lip of piston cup is facing inward (toward
spring and expander) and flat side is against
piston.
(3) Install spring and expander followed by
remaining piston cup and piston.
(4) Install boots on each end of cylinder and insert
push rods in boots.
(5) Install cylinder bleed screw.
INSTALLATION
(1) Install cylinder mounting bolts and tighten to
20 N´m (15 ft. lbs.) (Fig. 44).
(2) Connect brake line to cylinder and tighten to
14 N´m (124 in. lbs.).
(3) Install the brake shoe return springs.
(4) Remove the brake pedal prop rod.
(5) Install the brake drum.
(6) Install the wheel and tire assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(7) Bleed base brake system (Refer to 5 - BRAKES
- STANDARD PROCEDURE).
PARKING BRAKE
DESCRIPTION
The parking brake is a hand lever and cable oper-
ated system used to apply the rear brakes.
OPERATION
A hand operated lever in the passenger compart-
ment is the main application device. The front cable
is connected between the hand lever and the rear
cables with an equalizer.
The rear cables are connected to the actuating
lever on each primary brake shoe. The levers are
attached to the brake shoes by a pin either pressed
into, or welded to the lever. A clip is used to secure
the pin in the brake shoe. The pin allows each lever
to pivot independently of the brake shoe.
To apply the parking brakes, the hand lever is
pulled upward. This pulls the rear brake shoe actu-
ating levers forward, by means tensioner and cables.
As the actuating lever is pulled forward, the parking
brake strut (which is connected to both shoes), exerts
Fig. 44 WHEEL CYLINDER
1 - WHEEL CYLINDER
2 - SUPPORT PLATE
Fig. 45 Wheel Cylinder Components±Typical
1 - SPRING
2 - CYLINDER
3 - PISTON CLIP
4 - BOOT
5 - PUSH ROD
6 - PISTON
7 - BLEED SCREW
8 - CUP EXPANDERS
KJBRAKES - BASE 5 - 29
WHEEL CYLINDERS (Continued)