1995 JEEP YJ Service And Repair Manual

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Page 169 of 2158

JEEP YJ 1995 Service And Repair Manual the bore surface is normal and acceptable but only if
the surface is in good condition.
Replace the cylinder if the bore is scored, corroded,
or pitted.Do not hone the cylinder bore in an at-
tempt to

Page 170 of 2158

JEEP YJ 1995 Service And Repair Manual (5) Remove air cleaner housing from engine com-
partment.
(6) Disconnect wire from combination valve pres-
sure differential switch (Fig. 9). Do not pull wire to
disconnect. Unsnap lock tabs on wire c

Page 171 of 2158

JEEP YJ 1995 Service And Repair Manual (17) Remove nuts attaching master cylinder to
booster studs and remove cylinder (Fig. 16).
(18) Remove master cylinder reservoir cap and
drain fluid.
RESERVOIR REPLACEMENT (2-PIECE MASTER
CYLINDER)
(1

Page 172 of 2158

JEEP YJ 1995 Service And Repair Manual (5) Remove reservoir by rocking it to one side and
pulling free of grommets (Fig. 19).
(6) Remove old grommets from cylinder body (Fig.
20).
(7) Lubricate new grommets with clean brake
fluid.
(8) Inst

Page 173 of 2158

JEEP YJ 1995 Service And Repair Manual (7) Install combination valve as follows:
(a) Work combination valve and brakelines into
position.
(b) Slide combination valve bracket onto booster
stud closest to driver side fender (Fig. 25). Then i

(7) Install combination valve as follows:
(a) Work combination valve and brakelines into
position.
(b) Slide combination valve bracket onto booster
stud closest to driver side fender (Fig. 25). Then in-
stall bracket attaching nut but do not fully tighten
nut at this time.
(c) Connect flex lines to HCU. Start lines by
hand to avoid cross threading.
(8) Swing rear brakeline around and connect it to
master cylinder. Then install and connect frontbrakeline to combination valve and master cylinder.
Start brakelines by hand to avoid cross threading.
(9) Tighten combination valve bracket attaching
nut to 25 Nzm (220 in. lbs.) torque.
(10) Install S-clip on lines from master cylinder to
combination valve.
(11) Connect wire to pressure differential switch in
combination valve.
(12) Fill and bleed brake system.
(13) Tighten brakeline fittings to 15-18 Nzm (130-
160 in. lbs.) at HCU and master cylinder and to
18-24 Nzm (160-210 in. lbs.) at combination valve.
(14) Connect brake booster and canister vacuum
hoses to manifold fittings.
(15) Install air cleaner housing, filter, cover, and
hose.
(16) Connect PCV hose.MASTER CYLINDER BENCH BLEEDING
The bench bleeding procedure for both master cyl-
inder types is basically the same. The only difference,
is that both bleed tubes go in the same filler neck
opening on cylinders with the nylon reservoir.
(1) On models with integral master cylinder, fill
each reservoir to within 6 mm (1/4 in.) of rim. On
two-piece cylinder, fill reservoir to FULL mark.
(2) Fabricate and install master cylinder bleed
tubes. Be sure tube ends are submerged in brake
fluid. Tubes can be fabricated from rubber hose, or
copper tubing and spare brakeline fittings.
(3) Using push rod or wooden dowel (Fig. 26),
stroke cylinder pistons fully into bore;then allow pis-
tons to return under spring pressure. Repeat this op-
eration until air bubbles cease to appear in fluid.
(4) Remove bleed tubes, cap outlet ports, and in-
stall reservoir cap, or cover and seal.
Fig. 24 Master Cylinder Installation
Fig. 25 Combination Valve Installation
Fig. 26 Typical Method Of Bleeding Master Cylinder
(One-Piece Cylinder Shown)
JMASTER CYLINDERÐCOMBINATION VALVE 5 - 21

Page 174 of 2158

JEEP YJ 1995 Service And Repair Manual POWER BRAKE BOOSTERÐBRAKE PEDALÐBRAKELIGHT SWITCH
INDEX
page page
Brake Pedal Installation..................... 31
Brake Pedal Removal...................... 31
Brakelight Switch Adjustment..........

Page 175 of 2158

JEEP YJ 1995 Service And Repair Manual POWER BRAKE BOOSTER OPERATION
Booster Components
The booster assembly consists of a housing divided
into separate chambers by two internal diaphragms
(Fig. 2). The outer edge of each diaphragm is at-

Page 176 of 2158

JEEP YJ 1995 Service And Repair Manual POWER BRAKE BOOSTER REMOVAL
(XJ WITH ABS)
(1) Disconnect vacuum and vent hoses at air
cleaner cover.
(2) Loosen clamp securing air cleaner hose to in-
take manifold. Use screwdriver to tap clamp loose

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