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tech
Replacing Your CJ Front
Brakes
After several seasons of
off-roading your Jeep's brakes will probably need replacing.
Mud, dust, and small rocks get stuck on the rotors and act
like sand paper on your Jeep's brakes. This CJ-7
needed a brake job from just such exposure.
We decided to replace the
rotors along with the pads to completely freshen up the
Jeep's braking system. The old rotors were pretty
chewed up from trail debris. We also figured to
replace the inner wheel hub seal since it was apart.
Pre-work parts and tools
list
Procedure
-
Jack up the vehicle and
place jack stands under the axle. Confirm the Jeep
is supported.
-
Remove the wheels
-
Remove the calipers by
loosening the 2 torx bolts. (81 - 86 CJ) 76 - 80
CJ's use a center bolt that holds a shim that is knocked
out by tapping it lightly with a drift.
-
Place the calipers out of
the way as to not damage the brake lines.
-
Remove the old pads from
the caliper mount.
before disassembly |
removing the capliper |
caliper |
- Remove the hub assembly.
This Jeep is equipped with Warn Premium lockout hubs.
They are removed by removing the end cap, removing the
axle snap ring, then removing the hub gear assembly.
- After the hub is removed
the outer wheel hub nut can be removed followed by a
washer, then remove the inner nut and washer.
- At this point the wheel
hub and bearing should pull right off the spindle.
removing the hub |
wheel hub nut |
empty spindle |
Installing a new seal and
preparing the bearings
- Remove the old seal from
the back of the wheel hub using a seal puller.
- Remove the outer and
inner bearing. If they are in good condition clean
the bearings and repack with a quality grease. We
used Valvoline Durablend Grease and a bearing packer.
A bearing packer is an excellent tool for any
do-it-yourselfer. A bearing is placed in the
packer and grease is pumped in through a fitting and is
forced through the cage filling the bearing with grease.
- Replace the bearings if
they are pitted or show signs of wear or water damage.
removing Seal |
cleaned bearings |
bearing packer |
Removing the rotor and
installation of a replacement
- A press would be handy
at this point but a heavy hammer and an old lug nut will
work fine.
- Place the old lug onto
the bolt and tap with the hammer to drive the lug out of
the back of the hub.
- After they are all
removed the rotor and hub will separate.
- Install the new rotor
onto the hub and place a lug bolt into the hole lining
up the splines.
- Put a small amount of
grease onto the lug bolt's threads.
- Using an open lug nut
with the flat end in against a washer thread the nut
until it pulls the lug all the way into the hub.
Repeat until they are all installed
removing the lugs |
rotor and hud separated |
new rotor |
new rotor and hub assembled |
Hub reassembly
- Install the packed inner
bearing into the back of the hub. Note: the inner
bearing is identified by using smaller rollers and a
larger diameter center.
- Gently tap the new seal
into place.
- Clean the spindle paying
attention to the seal contact surface.
- Install the hub onto the
spindle. Rotate to confirm a proper seat.
- Grease the inside of the
hub filling it with grease.
- Insert the outer bearing
into the hub, press it all the way in until the hub is
tight.
- Install the inner washer
and inner nut. Tighten the nut enough to remove
excess play but not interfere with hub movement.
- Install the outer washer
and nut. Tighten the outer nut to prevent movement
of the inner nut.
- Install the lockout hub
gear assembly and axle snap ring. Install the hub
cap.
installing the seal |
inner washer |
inner nut |
outer washer and nut |
Installing the new brake
pads
- Clean the rotors to
remove grease and dirt.
- Install the pads and the
anti-rattle clips into the caliper mounts. Note:
The inner pad is slightly smaller than the outer.
- Using a clamp squeeze
the caliper's reservoir to press the piston back into
the caliper.
- Install the caliper back
onto the mount an tighten the bolts.
- Pump the brakes a few
times to allow the calipers to adjust.
- Install the wheels and
test.
- Re-torque the lug nuts
to verify tightness after a short drive to assure that
the lug bolts have seated tightly.
- Drive the Jeep for a
bit, check the wheel hub (by touching it) for excessive
heat. If it is hot the bearing may be installed
too tightly. It would be necessary to disassemble
the wheel to correct this.
new pads |
squeezing the caliper |
finished! |
This Jeep is ready for a new
season of tackling the trails. It is comforting
knowing the brakes are going to stop and the bearings are
well lubed and sealed.
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