wheel JEEP YJ 1995 Service And Manual PDF

(4) Install new spring nuts on wheel studs.
(5) Install wheel and lower vehicle.
DISC BRAKE ROTOR THICKNESS
Rotor minimum usable thickness is 22.7 mm (0.89
in.). This dimension is either cast, or stamped on the
rotor hub, or outer edge.
Measure rotor thickness at the center of the brake-
shoe contact surface.
Replace the rotor if worn below minimum thick-
ness. Also replace the rotor if refinishing would re-
duce thickness below the allowable minimum.
DISC BRAKE ROTOR RUNOUT
Check rotor lateral runout whenever pedal pulsa-
tion, or rapid, uneven brakelining wear has occurred.
On 4-wheel drive models, the rotor must be se-
curely 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 as shown (Fig. 27).
Use a dial indicator to check lateral runout (Fig.
27).
Maximum allowable rotor lateral runout is 0.13
mm (0.005 in.).
Check lateral runout with a dial indicator (Fig. 28).
Excessive lateral runout will cause brake pedal pul-
sation and rapid, uneven wear of the brakeshoes.
Maximum allowable rotor runout for all models is
0.12 mm (0.005 in.).
DISC BRAKE 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 ap-
proximately 2 cm (3/4 in.) from the rotor outer cir-
cumference for each measurement (Fig. 29).
Thickness should notvaryby more than 0.013 mm
(0.0005 in.) from point-to-point on the rotor. Refinish
or replace the rotor if necessary.
Fig. 26 Rotor And HubFig. 27 Securing4x4Rotor For Lateral Runout Check
Fig. 28 Typical Method Of Checking Rotor Lateral
Runout
Fig. 29 Measuring Rotor Thickness Variation
5 - 52 DISC BRAKESJ

WHEEL NUT TIGHTENING
The wheel attaching nuts must be tightened prop-
erly to ensure efficient brake operation. Overtighten-
ing the nuts or tightening them in the wrong
sequence can cause distortion of the brake rotors and
drums. Impact wrenches are not really recommended
for tightening wheel nuts. A torque wrench should be
used for this purpose.
A light coat of LPS Anti-Corrosion spray lube
around the hub face and on the studs will cut down
on rust/corrosion formation.The correct tightening sequence is important in
avoiding rotor and drum distortion. The correct se-
quence is in a diagonal crossing pattern (Fig. 32).
Recommended torque range for XJ/YJ wheel nuts
is 108-149 Nzm (80-110 ft. lbs.). Preferred set-to
torque is 129 Nzm (95 ft. lbs.) torque.
Seat the wheel and install the wheel nuts finger
tight. Tighten the nuts in the sequence to 1/2 the re-
quired torque. Then repeat the tightening sequence
to final specified torque.
Fig. 31 Preferred Rotor Surface Finish
Fig. 32 Wheel Nut Tightening Sequence
5 - 54 DISC BRAKESJ

DRUM BRAKES
INDEX
page page
Brake Drum Refinishing.................... 58
Drum Brake Adjustment.................... 57
Drum Brakeshoe Installation................. 55
Drum Brakeshoe Removal................... 55
Support Plate Replacement.................. 58Wheel Cylinder Installation.................. 58
Wheel Cylinder Overhaul.................... 57
Wheel Cylinder Removal.................... 57
Wheel Nut Tightening...................... 59
DRUM BRAKESHOE REMOVAL (Figs. 1 and 2)
(1) Raise vehicle and remove rear wheels.
(2) Remove and discard spring nuts securing
drums to wheel studs.
(3) Remove brake drums. If drums prove difficult
to remove, retract brakeshoes. Remove access plug at
the rear of backing plate and back off adjuster screw
with brake tool and screwdriver.
(4) Remove U-clip and washer securing adjuster
cable to parking brake lever.
(5) Remove primary and secondary return springs
from anchor pin with Brake Spring Plier Tool 8078.
(6) Remove holddown springs, retainers and pins
with standard retaining spring tool.
(7) Install spring clamps on wheel cylinders to hold
pistons in place.
(8) Remove adjuster lever, adjuster screw and
spring.
(9) Remove adjuster cable and cable guide.
(10) Remove brakeshoes and parking brake strut.(11) Disconnect cable from parking brake lever and
remove lever.
DRUM BRAKESHOE INSTALLATION
(1) Clean support plate with Mopar brake cleaner.
Replace support plate if worn, or rusted through at
any point. Do not attempt to salvage, or reuse a dam-
aged support plate.
(2) If new drums are being installed, remove pro-
tective coating with Mopar Carb cleaner followed by
final rinse with Mopar brake cleaner. A scotch brite
pad, or steel wool can also be used to help loosen and
remove coating if desired.It is not necessary to
machine drums to remove the coating.
(3) Clean and lubricate anchor pin with light coat
of Mopar multi-mileage grease.
(4) Apply Mopar multi-mileage grease to brakeshoe
contact surfaces of support plate (Figs. 3 and 4).
(5) Lubricate adjuster screw threads and pivot
with Mopar spray lube.
Fig. 1 Nine Inch Drum Brake Components
JDRUM BRAKES 5 - 55

(6) Attach parking brake lever to secondary brake-
shoe. Use new washer and U-clip to secure lever.
(7) Remove wheel cylinder clamps.
(8) Attach parking brake cable to lever.
(9) Install brakeshoes on support plate. Secure
shoes with new holddown springs, pins and retainers.
(10) Install parking brake strut and spring.
(11) Install guide plate and adjuster cable on an-
chor pin.
(12) Install primary and secondary return springs.
(13) Install adjuster cable guide on secondary shoe.
(14) Lubricate and assemble adjuster screw (Fig.
5).
(15) Install adjuster screw, spring and lever and
connect to adjuster cable.(16) Adjust shoes to drum as described in following
procedure.
(17) Install wheel/tire assemblies and lower vehi-
cle.
(18) Verify firm brake pedal before moving vehicle.
Fig. 2 Ten Inch Drum Brake Components
Fig. 3 Shoe Contact Surfaces (9-Inch Support Plate)
Fig. 4 Shoe Contact Surfaces (10-Inch Support
Plate)
5 - 56 DRUM BRAKESJ

DRUM BRAKE ADJUSTMENT
Rear drum brakes are equipped with a self adjust-
ing mechanism. Under normal circumstances, the
only time adjustment is required is when the shoes
are replaced, removed for access to other parts, or
when one or both drums are replaced.
The only tool needed for adjustment is a standard
brake gauge.
Adjustment is performed with the brakeshoes in-
stalled on the support plate. Procedure is as follows:
ADJUSTMENT PROCEDURE
(1) Raise and support vehicle rear end and remove
wheels and brake drums.
(2) Verify that left/right automatic adjuster lever
and cable are properly connected.
(3) Insert brake gauge in drum. Expand gauge un-
til gauge inner legs contact drum braking surface.
Then lock gauge in position (Fig. 6).
(4) Reverse gauge and install it on brakeshoes
(Fig. 6). Position gauge legs at shoe centers as
shown. If gauge does not fit (too loose or tight), ad-
just shoes.
(5) Pull shoe adjuster star wheel away from ad-
juster lever.(6) Turn adjuster star wheel (by hand) to expand
or retract brakeshoes. Continue adjustment until
gauge outside legs are light drag-fit on shoes (Fig. 7).
(7) Repeat adjustment at opposite brakeshoe as-
sembly.
(8) Install brake drums and wheels and lower ve-
hicle.
(9) Make final adjustment as follows:
(a) Drive vehicle and make one forward stop fol-
lowed by one reverse stop.
(b) Repeat procedure 8-10 times to actuate self
adjuster components and equalize adjustment.
(c)Bring vehicle to complete standstill at
each stop. Incomplete, rolling stops will NOT
activate adjuster mechanism.
WHEEL CYLINDER REMOVAL
(1) Raise vehicle and remove wheel.
(2) Disconnect brakeline at wheel cylinder.If cyl-
inder brakeline fitting is hard to break loose,
spray generous amount of Mopar Rust Pene-
trant between fitting and line and around fit-
ting threads in wheel cylinder. Note that it may
require a few minutes for penetrant to work.
(3) Remove brakeshoes.
(4) Remove bolts attaching wheel cylinder to sup-
port plate and remove cylinder.
WHEEL CYLINDER OVERHAUL (Figs. 8 and 9)
(1) Remove links.
(2) Remove dust boots.
(3) Remove cups and pistons. Discard cups.
(4) Remove and discard spring and expander.
(5) Remove bleed screw.
(6) Clean cylinder, pistons and links with Mopar
brake cleaner.
(7) Inspect cylinder bore and pistons. Light discol-
oration of bore is acceptable. However, replace cylin-
der if bore and pistons are scored, pitted, or corroded.
Fig. 5 Adjuster Screw Components (9-Inch Brake)
Fig. 6 Adjusting Gauge To Brake Drum
Fig. 7 Adjusting Brakeshoes To Gauge
JDRUM BRAKES 5 - 57

Do not hone cylinder bores or polish pistons.
Replace cylinder as an assembly if bore is dam-
aged.
(8) Install bleed screw.
(9) Coat cylinder bore, pistons, cups and expander
with brake fluid and reassemble cylinder compo-
nents. Be sure piston cup lips face expander.
WHEEL CYLINDER INSTALLATION
(1) Apply small bead of silicone sealer around cyl-
inder mounting surface of support plate.
(2) Start brakeline in wheel cylinder fitting by
hand.
(3) Align and seat wheel cylinder on support plate
(Fig. 10).
(4) Install cylinder mounting bolts (Fig. 10).
Tighten bolts to 10 Nzm (90 in. lbs.) torque.(5) Tighten brakeline fitting to 15 Nzm (132 in.
lbs.) torque.
(6) Install brakeshoes. Adjust shoes to drum with
brake gauge.
(7) Install brake drums and lower vehicle.
(8) Fill master cylinder and bleed brakes.
SUPPORT PLATE REPLACEMENT
The support plate should cleaned and inspected
whenever the drum brake components are being ser-
viced.
Check the support plate for wear, or rust through
at the contact pads and replace the plate if necessary.
Be sure to lubricate the contact pads with Mopar
multi-mileage grease before shoe installation. Lubri-
cation will avoid noisy operation and shoe bind.
(1) Raise vehicle and remove wheel/tire assembly.
(2) Remove brake drum, brakeshoes, and wheel
cylinder.
(3) Remove axle shaft as described in Group 3.
(4) Remove support plate attaching nuts and re-
move support plate.
(5) Clean axle tube flange. If gasket is not used on
flange, apply thin bead of silicone adhesive/sealer to
flange.
(6) Position new support plate on axle tube flange.
(7) Apply Mopar Lock N9Seal, or Loctite 242 to
support plate attaching nuts. Then install and
tighten nuts.
(8) Apply light coat of Mopar multi-mileage grease
to contact pads of new support plate.
(9) Install wheel cylinder and brakeshoes.
(10) Adjust brakeshoes to drums. Refer to proce-
dure in this section.
(11) Bleed brakes.
(12) Install wheel and tire assembly.
(13) Adjust parking brake cable tensioner. Refer to
procedure in Parking Brake section.
(14) Lower vehicle and verify proper service brake
and parking brake operation.
BRAKE DRUM REFINISHING
Brake drums can be machined to restore the brak-
ing surface. Use a brake lathe to clean up light scor-
ing and wear.
CAUTION: Never refinish a brake drum if machining
will cause the drum to exceed maximum allowable
brake surface diameter.
Brake drums that are warped, distorted, or se-
verely tapered should be replaced. Do not refinish
drums exhibiting these conditions. Brake drums that
are heat checked or have hard spots should also be
replaced.
Fig. 8 Wheel Cylinder (9-Inch Brake)
Fig. 9 Wheel Cylinder (10-Inch Brake)
Fig. 10 Wheel Cylinder Mounting
5 - 58 DRUM BRAKESJ

If the brake drums are heavily coated with rust,
clean and inspect them carefully. Rust damage on
high mileage drums can be severe enough to require
replacement.
New drums have a protective coating that should
be removed before installation.It is not necessary
to machine a drum to remove this coating. The
coating is easily removed with Mopar carb
cleaner followed by a rinse with Mopar brake
cleaner. A scotch brite pad, or steel wool can
also be used to help loosen and remove the
coating if desired.
The maximum allowable diameter for the drum
braking surface is usually indicated on the drum
outer face (Fig. 11).
WHEEL NUT TIGHTENING
The wheel attaching lug nuts must be tightened
properly to ensure efficient brake operation. Over-tightening the nuts or tightening them in the wrong
sequence can cause distortion of the brake rotors and
drums.
Impact wrenches are not recommended for tighten-
ing wheel nuts. A torque wrench should be used for
this purpose.
A light coat of LPS Anti-Corrosion spray lube
around the hub face and on the studs will cut down
on rust/corrosion formation.
The correct tightening sequence is important in
avoiding rotor and drum distortion. The correct se-
quence is in a diagonal crossing pattern (Fig. 12).
Recommended torque range for XJ/YJ wheel nuts
is 109-150 Nzm (80-110 ft. lbs.).
Seat the wheel and install the wheel nuts finger
tight. Tighten the nuts in the sequence to half the re-
quired torque. Then repeat the tightening sequence
to final specified torque.
Fig. 11 Typical Location Of Brake Drum Refinish
Limit
Fig. 12 Wheel Nut Tightening Sequence
JDRUM BRAKES 5 - 59

PARKING BRAKE REAR CABLE REPLACEMENT (XJ)
(1) Raise vehicle and loosen equalizer nuts until
rear cables are slack.
(2) Disengage cable from equalizer and remove ca-
ble clip and spring (Fig. 15).
(3) Remove rear wheel and brake drum.
(4) Remove secondary brakeshoe and disconnect
cable from lever on brakeshoe.
(5) Compress cable retainer with worm drive hose
clamp (Fig. 16) and remove cable from backing plate.
(6) Install new cable in backing plate. Be sure ca-
ble retainer is seated.
(7) Attach cable to lever on brakeshoe and install
brakeshoe on backing plate.
(8) Adjust brakeshoes to drum with brake gauge.(9) Install brake drum and wheel.
(10) Engage cable in equalizer and install equal-
izer nuts (Fig. 15).
(11) Adjust parking brakes. Refer to procedure in
this section.
PARKING BRAKE FRONT CABLE REPLACEMENT
(YJ)
(1) Raise vehicle.
(2) Remove equalizer nuts (Fig. 17).
(3) Remove front cable from equalizer (Fig. 17).
(4) Remove cable-to-frame bracket clip.
(5) Lower vehicle.
(6) Move front carpeting away from pedal.
(7) Compress clip securing cable to pedal frame
(Fig. 17). Use hose clamp to compress clip.
(8) Disconnect cable from pedal retainer and re-
move cable.
(9) Remove grommet (Fig. 17) from old cable and
transfer it to new cable, if necessary.
(10) Install new cable in floorpan and connect it to
pedal assembly.
(11) Seat cable grommet in floorpan.
(12) Raise the vehicle.
(13) Install cable-to-frame retaining clip.
(14) Insert cable in equalizer and install equalizer
washer and nuts.
(15) Adjust parking brakes as described in Service
Adjustment section.
Fig. 14 Parking Brake Pedal Assembly (YJ)
Fig. 15 Parking Brake Cables (XJ)
Fig. 16 Compressing Rear Cable Retainer
JPARKING BRAKES 5 - 67

PARKING BRAKE REAR CABLE REPLACEMENT (YJ)
(1) Raise vehicle and loosen equalizer nuts (Fig.
17).
(2) Remove clamp and cotter pin attaching rear ca-
ble to equalizer and remove cable.
(3) Remove cable clips.
(4) Remove rear wheel and brake drum.
(5) Remove secondary brakeshoe and disconnect
cable from lever on brakeshoe.
(6) Compress cable retainer with hose clamp (Fig.
16) and remove cable from backing plate.
(7) Install new cable in backing plate. Be sure ca-
ble retainer lock tabs are engaged in plate.
(8) Install secondary brakeshoe.
(9) Adjust brakeshoes to brake drum and install
drum and wheel.
(10) Install cable in equalizer. Secure cable with
retainer and cotter pin.
(11) Install cable clips.
(12) Adjust parking brakes. Refer to procedure in
this section.
PARKING BRAKE SWITCH
The parking brake switch is located on the lever
assembly on XJ models, or on the foot pedal assem-
bly on YJ models (Fig. 18). Switch replacement is de-
scribed in the parking brake lever or foot pedal
removal/installation procedures in this section.
Fig. 17 Parking Brake Components (YJ)
Fig. 18 Parking Brake Switch Location
5 - 68 PARKING BRAKESJ

PARKING BRAKE CABLE TENSIONER ADJUSTMENT
(XJ/YJ)
Parking brake adjustment is only necessary
when the tensioner, or a cable has been re-
placed or disconnected for service. When ad-
justment is necessary, perform adjustment only
as described in the following procedure. This is
necessary to avoid faulty parking brake opera-
tion.
(1) Raise vehicle.
(2) Back off tensioner adjusting nut to create slack
in cables.
(3) Remove rear wheel/tire assemblies and remove
brake drums.
(4) Check rear brakeshoe adjustment with stan-
dard brake gauge. Also check condition of brake parts
as follows:
(a) Replace worn parts if necessary.Excessive
shoe-to-drum clearance, or worn brake com-
ponents will result in faulty parking brake
adjustment and operation.
(b) Verify that parking brake cables operate
freely and are not binding, or seized. Replace faulty
cables, before proceeding.
(c) Adjust rear brakeshoes shoes to drum.
(5) Reinstall brake drums and wheel/tire assem-
blies after brakeshoe adjustment is complete.
(6) Lower vehicle enough for access to parking
brake lever or foot pedal.Then fully apply parking
brakes. Leave brakes applied until adjustment
is complete.(7) Raise vehicle again.
(8) Mark tensioner rod 6.5 mm (1/4 in.) from ten-
sioner bracket (Fig. 19).
(9) Tighten adjusting nut at equalizer until mark
on tensioner rod moves into alignment with tensioner
bracket (Fig. 19).Do not loosen/tighten equalizer
adjusting nut for any reason after completing
adjustment.
(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.
Fig. 19 Placing Adjustment Mark On Tensioner Rod
JPARKING BRAKES 5 - 69