Comanche 4WD L4-150 2.5L VIN H TBI (1986)
Brake Caliper: Service and Repair
Disassembly and Assembly
Disassembly
1.
Clean outside of caliper with suitable solvent.
2.
Drain fluid from caliper and place clean shop cloths in caliper opposite piston.
3.
Slowly apply compressed air to caliper inlet port until piston pops out of bore.
4.
Remove and discard dust boot, using a suitable screwdriver. Use care to avoid scratching caliper piston bore.
5.
Remove and discard piston seal, using a suitable wooden or plastic tool.
6.
Remove bleeder screw and protective cap, if equipped.
7.
Remove and discard inner and outer bushings and plastic sleeves, if equipped.
8.
Clean all components with clean brake fluid and compressed air.
Assembly
1.
Lubricate piston bore and new piston seal with clean brake fluid.
2.
Install seal in bore groove by hand and lubricate piston with clean brake fluid.
3.
On 1980-81 CJ models, install bleeder screw and protective cap.
4.
On 1980-81 CJ models, if piston dust boot installation tool No. J-24837 is available, install boot and piston as follows:
a. Apply clean brake fluid to piston and new dust boot.
b. Position dust boot on installation tool with approximately 1/4 inch of tool extending beyond small lip of dust boot.
c. Place boot and tool assembly over piston bore, then reach through tool and work large lip of boot into boot groove in upper edge of piston
bore until boot is fully seated.
d. Apply clean brake fluid to caliper piston, then insert piston through tool and center piston in bore.
e. Press piston half way into bore using steady pressure on a hammer handle.
f.
Remove boot installer tool, then seat dust boot rubber lip in piston groove.
g. Press piston to bottom of bore using hammer handle.
5.
On 1980-81 CJ models, if piston dust boot installation tool is not available, install boot and piston as follows:
a. Apply clean brake fluid to piston bore.
b. Position dry dust boot on piston bore.
c. Reach through top of boot and work large lip of boot into boot groove at upper edge of bore until boot is fully seated.
d. Apply clean brake fluid to piston and small lip of dust boot.
e. Position piston over small lip of boot and apply approximately 15 psi compressed air into caliper fluid inlet port.
f.
With air pressure expanding boot, work piston into boot until boot lip seats in piston groove. When lip is fully seated, release air pressure.
g. Press piston to bottom of bore using hammer handle.
6.
On all except 1980-81 CJ models, proceed as follows:
a. Install new dust boot on piston, sliding metal retainer portion of boot over open end of piston and pulling boot rearward until boot lip seats in
piston groove.
b. Push metal retainer portion of boot forward until retainer is flush with rim at open end of piston, then snap boot fold into place.
c. Install piston into caliper bore, using care to avoid unseating piston seal.
d. Press piston to bottom of bore, then using tool No. J-33028 or equivalent, seat metal retainer portion of dust boot in counterbore at upper end
of bore.
e. Install bleeder screw, then new inner and outer bushings and plastic sleeves, if equipped, in caliper mounting ears.
