Emergency Brake Lever's 05 KJ CRD

kjjet · **Posted:** Sun Jan 20, 2013 3:47 pm

Had a brake noise this AM. Pulled the rear brakes and found the emergency brake L/H stuck on and all worn & busted. I can get all the parts but the 2 piece lever. The lever hooks to the E-brake cable and pushes the brakes toward the drums. It has 2 pieces and they are rusted as one.

Dose anyone know the P/N for the 2 piece lever for both L/H and R/H sides?

Thanks!

papaindigo · **Posted:** Sun Jan 20, 2013 4:18 pm

Jump over to Sir Sam's manual download link at http://colorado4wheel.com/manuals/Jeep/KJ/ and grab a copy of the parts manual. Take a look at the parking brake illustration. I think I see what you need, 1 piece same on both sides and 1 piece that's L vs R, but better you make the decision than I since I've never been in there.

kjjet · **Posted:** Sun Jan 20, 2013 4:40 pm

Will Do. THANK YOU! I have a parts manual at work but not here at home.

papaindigo · **Posted:** Sun Jan 20, 2013 4:45 pm

Grab copies of the 05 and 06 FSMs while there. The 05 lacks CRD cooling system data and diagnostic codes but has illustration keys while the 06 is the reverse. I owe Sir Sam the 05 cooling system pages but haven't had time to scan and index them yet.

kjjet · **Posted:** Sun Jan 20, 2013 5:31 pm

Per Manual Figure 4-120 Showes both pieces.
Item 3 05093392AA
Item 4 05093334AA
& 05093338AA

I beleve I will need 2ea of item 3 and 1ea of item 4 for L/H & R/H sides. I will make sure by calling jeep tomorrow.

MRausch82 · **Posted:** Sun Jan 20, 2013 6:31 pm

kjjet wrote:

Per Manual Figure 4-120 Showes both pieces.
Item 3 05093392AA
Item 4 05093334AA
& 05093338AA

I beleve I will need 2ea of item 3 and 1ea of item 4 for L/H & R/H sides. I will make sure by calling jeep tomorrow.

This stuff *may* come in the parking brake hardware kit... which you should be able to get from Advance or Napa. I have a set of Mopar shoes that I need to install. My hardware, at least on the left side, looks alright.

kjjet · **Posted:** Sun Jan 20, 2013 7:49 pm

I wish. They are a jeep parts $$$$$ I may take them to work and glass beed them tomorrow & maybe if i use some lubraplate on them, they will be ok. Will see.

MRausch82 · **Posted:** Sun Jan 20, 2013 8:30 pm

kjjet wrote:

I wish. They are a jeep parts $$$$$ I may take them to work and glass beed them tomorrow & maybe if i use some lubraplate on them, they will be ok. Will see.

Well there goes that idea then. Seems these parking brake shoes don't last for crap. Mine have been INOP for a while now. It looks to be a simple repair. Hopefully you'll be able to salvage what you have without having to resort to giving Mopar any $$.

kjjet · **Posted:** Mon Jan 21, 2013 1:57 pm

Called Jeep this AM, parts would be over $115 for 4 little steel parts. They said item 4 has been superseeded with new P/N's.

I just glass beeded all the parts. Looks good. I will reassamble with Lubraplate Lithium Grease. I think it will be good for a long time.

kjjet · **Posted:** Tue Jan 22, 2013 5:09 pm

I did get all the emergency brake parts installed and adjusted. (new drum/rotors, brake kit, pads, e-brake shoes and blasted e-brake levers) Drove it in the AM and at lunch adjusted again untill the e-brakes start to drag without the e-brake being pulled. Problem is when the e-brake handle is pulled it dose not start to make contact with the brakes untill its 3/4 or more from the top. At the top it will not hold the jeep on a hill. The manual states there is no adjustment for the cables.

Has anyone had this problem? Seems like lots of people are complaining about lack of e-brakes.

Is the answer to replace both cables? Did they stretch over time?

papaindigo · **Posted:** Wed Jan 23, 2013 7:53 am

If I am reading things correctly the tensioner, wherever that is, for the cables is set at the factory and may or may not be adjustable outside of the factory. However the brake assembly itself is "self-adjusting" although I don't offhand see an explanation as to how. On normal drum, which the parking brake is, brakes there is a sort of rachet mechanism associated with a star wheel that self-adjusts the distance of the shoes from the drum when the brake pedal is pressed while moving in reverse. Whether or not the parking brake adjusts the same way I cannot tell without actually looking at the mechanism.

What I can say is pg 5-38 of the 05 FSM shows how to manually adjust the star wheel which is what I suspect you need to do.

jeepdan · **Posted:** Wed Jan 23, 2013 9:29 am

I have had this problem with both of my CRDs.
For me, bead blasting and then greasing only lasts a year, then you are going to the trouble of doing it over again.
Believe me, it can be really difficult to get those levers out of there if they are seized really bad with rust.
I gave up and bought the new levers and struts from the dealer at $60.00 a wheel for CRD #1. The OEM replacements are heavily plated, and I haven't had any more trouble for two years (knock on wood). These parts do not come in any after market brake service kit.
As for CRD #2, I'm about to give in and buy new parts for it also. After bead blasting, I have tried never sieze, grease, and the last time I used RIG gun grease. So far the RIG has lasted the longest for lubricating the lever pivots.
The shoes aren't self adjusting, only a star wheel to get the correct clearance for the shoes.

kjjet · **Posted:** Wed Jan 23, 2013 9:36 am

Guys... I did replace and adjust everything in the back as stated above. But the cables will not pull the e-brakes tight enough. Jeep states the cables are not adjustable. BUT...I found a post that showes how to adjust. I will try it later today.

viewtopic.php?f=1&t=19141

kjjet · **Posted:** Wed Jan 23, 2013 12:05 pm

Wow..the e-brake works great now. I suggest adjusting the brakes first then the handle. (I think thats why Jeep dose not tell you, People would try the easy thing first)

papaindigo · **Posted:** Wed Jan 23, 2013 2:04 pm

Nice catch. I had found Jeepjeepster's post on doing it in the rear but had forgotten and not saved the how to in the front.

Emergency Brake Lever's 05 KJ CRD

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