I recently let the my FLJD install new rear brake pads and rotors in order to pass state inspection. the bill for the parts and labor justifies the purchase of the printed factory repair manual. yesterday, my bride took it out for a drive and returned home complaining of smells emanating from the right rear corner. a cursory look revealed way too much heat compared to the other three corners. a search of the net revealed enough scary stories vis-à-vis KJ brakes to make my skin crawl, it also placed the jeep at the top of the driveway in front of all others, who were thinking about breaking down. after picking up the rear of the jeep (wheels chocked and jack stands underneath), I checked to see whether the emergency brake was releasing. the e-brake checked out good, both rear wheels spun equally well when rotated. I then removed the right rear wheel to begin looking at the brakes for that wheel. after collapsing the caliper (c-clamp), I removed the caliper and checked the caliper pins for bending or galling and found none. I looked at the general condition of the caliper and found no leaks or damage. both brake pads were cracked, though the linings were intact. the rotor showed signs of heating, but there was no damage. I removed the rotor from the axle, cycled the emergency brake to observe that the brake was releasing (it was), I then checked that the emergency brakes shoes were adjusted properly (brake caliper) and found they were ok. by now, the nightmares of real brake work were beginning to creep in on all sides, but I still had a few aces. I looked at the pads and their mounting and they were fine (diamler-benz gets a nod for the best pad mounting I have seen). after reinstalling the caliper and pads, I began to look at the float function for the brake caliper. at this point it became apparent that the caliper was not as free as I would expect it to be; further investigation revealed that the brake backing plates were tight in the caliper yoke, a closer look reveal that the edges of the backing pads had enough of a burr on them from when the blanks were stamped out by the punch press they were made on to prevent the pads from moving freely in the yoke. a little quiet time with a file on the burrs, allowed me to square up the backing plates and verify that the pads could move freely in the caliper yokes by hand. after re-assembling the brakes, I took the KJ out for a ride and the right rear corner is now cooler than the other three corners. it sure beats the alternative that could surely happen as a result of doing nothing.

This problem may pop up again.
I have replaced a few of the calipers with the phenolic (plastic) piston. The pistons can swell with time. Just did right rear on my KJ. There is a metallic piston option available.

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Eddie Ott "I like fun" OI!IIII!IO

I had a similar issue a few years back. The right rear emergency brake shoes broke off. I would have this smell of over heated brake, but it would be sporadic. Not every time I drove, but maybe 1 in 7 times I would drive. One time I stopped at a light, just coming off the highway when this cloud of white smoke, smelling of hot brakes, went by my Jeep. I drove straight to the dealer, they pulled the wheel off and then the hub. The e-brake shoes just fell on the floor. They broke loose at some point. Those were stock parts from 2005 when I purchase her new and they lasted over 90,000 miles. Also, the heat was so bad, I poured a half gallon of water my tire and rim and thick steam just came off. So you might want to check your e-brake shoes.

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Uncle Fester
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2005 Liberty Renegade, Light Khaki - Yukon 4.10's, ARB Lockers F/R, ARB Deluxe Bull Bar Bumper, Warn M8000 winch, OME 927/948, JBA A-Arms, Goodyear Adventure with Kevlar 245/75-16

thanks for the replies. the e-brake shoes were in good shape, no cracks, reasonable adjustment, and the release mechanism appeared to work (anti-seized the friction points just in case). the plastic piston is worrisome, if this corner acts up again, I will find the metal piston replacements and install them, post haste. the horror stories of liberty's with brake failures or body rolls due to brakes are scary enough that this is nothing to monkey around with. I have a fair amount of experience with the personalities of german cars, so this one will be no different, imho. I will be sure to post should more happen with this.