Calipers Will Not Fit Over New Rotors - 1999 WJ - JeepForum.com
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Unread 08-27-2009, 11:09 AM   #1
netmaxweb
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Calipers Will Not Fit Over New Rotors - 1999 WJ

I'm trying to fix the warped rotors which have developed in my 1999 GC.

It still has the original Teves calipers which have long since been declared defective (and replaced by the Akebono of course). Anyway, after putting on new PBR rotors, which are about 1mm thicker than my old rotors, I am finding that the calipers will not fit over them. I have depressed the caliper pistons completely using clamps and channel lock pliers but still not enough clearance to fit.

Questions. Is there any way to adjust the clearance between the pads? Or are there different thicknesses of pads? Or is my new PBR rotor designed for use with the newer Akebono calipers only?

Personally I do not want to upgrade my brakes to the Akebonos at this time since the Teves have been working fine. So I'm looking for a solution which would allow the continued use of my Teves with my new PBR rotors.

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Unread 08-27-2009, 11:19 AM   #2
driabyor
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i would check with the parts store to make sure they gave you the right parts
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Unread 08-27-2009, 12:09 PM   #3
Turbonut
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You'll find that the rotors are the same for all WJ models, regardless of teh caliper style. Don't have the OE thivkness of the rotor for you to check, but worst case scenario, remove 1mm from the pad material.
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Unread 08-27-2009, 12:13 PM   #4
99avant
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Check to be sure you have the right parts. As said above, the rotors are the same.

I have stuck with the teves and have not regretted it.
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Unread 08-27-2009, 12:19 PM   #5
vosevichs
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Yes its the same rotor just different calipers.
Some info from wjjeeps

Front brakes

Rotor outside diameter: 305mm
Rotor thickness: 26mm, vented
Rotor weight: 16.5 lbs.
Caliper: Teves FN T48 / Akebono
Lining/Mu: BBA2014TA/0.32
Brake fluid: P/N 04318080AB (DOT 3 / MS-4574)


Jeep Grand Cherokee WJ - Front brake rotors
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Unread 08-27-2009, 12:28 PM   #6
northpaw
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1mm should not matter, if you pushed the caliper piston all the way back you should have like 5-10mm free play.
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Unread 08-27-2009, 12:38 PM   #7
Turbonut
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Quote:
Originally Posted by northpaw View Post
1mm should not matter, if you pushed the caliper piston all the way back you should have like 5-10mm free play.
He's stating that the pistons are pushed in as far as they will go and the pads still won't fit over the rotor.
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Unread 08-27-2009, 12:44 PM   #8
driabyor
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if you do take them back .... and are the correct ones... have the parts guy mic them ... compare them to another set.... they may have not been made right....
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Unread 08-27-2009, 01:07 PM   #9
northpaw
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1mm thicker disc still shouldnt be the problem.
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Unread 08-27-2009, 01:10 PM   #10
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Honestly I think the rotors are the right ones. In this case my Teves calipers are so defective that the pistons are not fully uncompressing. I can't even get them to uncompress fully even with tools like channel lock pliers and pry bars.

The pads on these Teves were not fully releasing from the rotors in the first place and that is probably what has caused the warping due to heat and friction.

Does anyone know a way to release any pressure from the brake system so I can uncompress the pistons? I am definitely not getting 5-10 mm of clearance to work with at the present.
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Unread 08-27-2009, 01:13 PM   #11
northpaw
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in that case I would get new calipers, I got new ones on my fron axle, since if the pistons already does not go all the way, you will end up destroying a new set of rotors, since the pistons will get worse, until they lock the brake completely as they did on mine
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Unread 08-27-2009, 02:12 PM   #12
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Quote:
Originally Posted by netmaxweb View Post
Does anyone know a way to release any pressure from the brake system so I can uncompress the pistons? I am definitely not getting 5-10 mm of clearance to work with at the present.
Are you compressing the piston while the master cylinder cover is on or off? I always do it with the cover removed, but you gotta keep an eye on the fluid and make sure it's not overflowing the master cylinder.
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Unread 08-27-2009, 03:36 PM   #13
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Whenever I have done the brakes on my WJs, I always had to struggle a little to pull the calipers off and put them back on, but I was able to get it done. When you pushed the pistons back, were you able to try putting the caliper on the rotor before releasing the pressure you used to push them back? To me it seemed that the pistons moved forward slightly after releasing the pressure.
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Unread 08-28-2009, 03:25 PM   #14
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Whenver I do my brakes I use a big c-clamp to compress the caliper pistons. The WJ is the first vehicle I've ever done with more than one piston in the caliper and I noticed on the first one that when I compressed one piston, the other would push back out. I kept alternating between the two until they were both compressed all the way in. For the other side, I just used the old pad to compress them both at the same time.
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Unread 08-28-2009, 05:50 PM   #15
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This may be a bit overly simple but it does make a difference. Did you pull the cap off the break fluid reservoir??? If not you will NOT be able to compress the pistons to enough to put the caliper back on. (With pads anyway.)
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