Tools You'll Likely Need:
* Jack and jack stands
* Wheel chocks
* Lug wrench
* Socket wrench set (metric)
* Wrenches (metric)
* Brake caliper pliers or C-clamp (to compress the caliper piston)
* Wire brush or brake cleaner
* New brake pads and possibly rotors (inspect for wear)
* Possibly a torque wrench
Procedure:
1. Safety First: Securely jack up the Jeep and place it on jack stands. Chock the front wheels. Disconnect the negative battery terminal.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Inspect the Brake System: Examine the brake pads, rotors, and caliper for wear and tear. Note the position of any components before removing anything.
4. Remove the Caliper:
* Locate the caliper mounting bolts: These are usually two bolts holding the caliper to the caliper bracket.
* Remove the caliper bolts: Use the appropriate socket and wrench to carefully remove these bolts. Sometimes they can be stubborn and require penetrating oil.
* Support the caliper: Once the bolts are removed, carefully support the caliper with a bungee cord or wire to prevent it from hanging by the brake line. This prevents stress on the brake line.
5. Compress the Caliper Piston:
* Use a caliper compression tool: This is the safest and easiest method. Slowly and evenly compress the piston until the pads are clear of the rotor.
* Alternative (Less Recommended): If you don't have a tool, you can carefully use a C-clamp to compress the piston. Be very gentle to avoid damaging the piston seal. Important: Turn the piston as you compress to avoid damaging the seal.
6. Remove the Brake Pads: Once the piston is compressed, the brake pads should slide out of the caliper. Note the orientation of the pads and shims – they usually have a wear indicator.
7. Remove the Rotor (if needed): If you're replacing the rotor, you'll need to remove it. This typically involves removing any caliper bracket retaining bolts and then sliding the rotor off the axle. Some models may have a retaining nut on the axle, while others simply slide off. This will require a hammer and punch and careful tapping to avoid damage. Consult your repair manual for specifics.
8. Inspect and Replace (as needed): Inspect everything for wear and tear. Replace the rotors and brake pads as necessary. Clean any rust or dirt from the caliper bracket.
9. Reassembly:
* Install new pads: Install the new brake pads, making sure they're properly seated.
* Mount the caliper: Carefully attach the caliper back to the bracket and bolt it down tightly. Ensure that the caliper is properly aligned.
* Install the rotor: If you replaced the rotor, install the new one.
* Install the wheel: Put the wheel back on and tighten the lug nuts.
* Lower the vehicle: Carefully lower the vehicle from the jack stands.
10. Bleed the Brakes: After reassembly, you will likely need to bleed the brakes to remove any air that may have entered the system during the repair. This is a crucial step to ensure proper brake function. You'll need a brake bleeder kit. Again, consult your repair manual for the specific bleeding procedure.
11. Test the Brakes: Test the brakes carefully and thoroughly before driving.
Important Notes:
* This is a general guide. Specific procedures may vary slightly depending on your Jeep's exact model and trim level.
* Always consult a repair manual specific to your 2004 Jeep Wrangler TJ before starting any repairs.
* If you're uncomfortable performing this repair yourself, take it to a qualified mechanic. Improper brake repair can be extremely dangerous.
Remember, safety is the top priority when working on your vehicle's brakes. Take your time, be methodical, and if you're unsure about anything, seek professional help.
