Rotor Service - Jeep 1979 CJ-5 Technical & Service Manual

26-50 BRAKES
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Fig. 2G-54
Caliper Piston instaiiation
(2) Mount dust boot on Installer Tool J-24837 (fig.
2G-52). Allow approximately 1/4 inch (6.35 mm) of tool
to extend beyond small lip of dust boot.
(3) Position assembled boot and installer tool over
piston bore. Reach through installer tool and work large
lip of boot into boot groove in upper edge of piston bore
(fig. 2G-53). Be sure boot is completely seated in groove.
(4) Lubricate caliper piston with brake fluid.
(5) Insert piston through installer tool and center
piston in bore.
(6) Press piston half-way into bore. Use hammer
handle and steady pressure to install piston (fig. 2G-54).
Do not strike hammer handle or piston to install. Piston
must be pressed into bore only.
(7) Remove boot installer tool.
(8) Seat rubber lip of dust boot in piston groove.
(9) Press piston to bottom of bore using hammer
handle.
(10) Inspect rotor and install caliper and brakeshoes.
Refer to Installation.
Piston and Boot installation without Installer Tool
(1) Lubricate piston bore with brake fluid.
(2) Position dust boot on piston bore. Do not lubri-
cate boot.
(3) Reach through top of boot and work large lip of
boot into boot groove at upper edge of bore. Be sure boot
is completely seated in groove.
(4) Lubricate piston and small lip of dust boot with
brake fluid.
(5) Position piston over small lip of boot.
(6) Hold piston in position over boot lip and direct
reduced air pressure of approximately 15 psi (112 kPa)
compressed air into caliper fluid inlet port.
N O T E : Reduce air pressure to a maximum of 15 psi
(112 kPa) by closing air supply valve completely; then
opening it approximately 1/1+ to 1/2 turn.
(7) As air pressure expends boot, carefully work
piston into boot until boot lip seats in piston groove.
When boot lip is seated in piston groove, release air
pressure.
(8) Press piston to bottom of bore using hammer
handle.
(9) Inspect rotor and install caliper and brakeshoes.
Refer to Installation.
Installation
(1) Check rotor lateral runout and thickness varia-
tion. Inspect rotor for scoring, cracks, and broken venti-
lating ribs. Refer to Rotor Service for procedures.
(2) Install brakeshoes and caliper. Refer to Bra-
keshoe Replacement—CJ Models.
(3) Install replacement washers on brake line con-
nector or fitting and connect brake line to caliper.
Tighten brake line bolt to 160 inch-pounds (18 N*m)
torque. Or, if equipped with brake line fitting, tighten
fitting to 25 foot-pounds (34 N # m ) torque.
(4) Fill master cylinder to within 1/4 inch (6.35
mm) of reservoir rims.
(5) Press brake pedal firmly several times to seat
brakeshoes.
(6) Refill master cylinder if necessary and bleed
brakes. Refer to Brake Bleeding.
(7) Install wheels.
(8) Lower vehicle.
(9) Check brake operation before moving vehicle.
ROTOR SERVICE
The hub and rotor are cast as a single unit. The hub
contains the wheel bearings and wheel mounting studs.
The hollow-cast rotor section has integral ventilating
fins and provides the contact surfaces that the brake-
shoes are pressed against.
The hub and rotor are serviced as an assembly only. If
either section is damaged, replace the complete
assembly.
Rotor service is extremely important because rotor
tolerances must be accurate to ensure proper brake op-
eration. Rotor service involves inspection, measure-
ment, and refinishing or replacement where indicated.
Inspection
(1) Raise vehicle and remove wheels.