Replace pads and rotors as a set on a vehicle this old — a $35 aftermarket rotor and $40 pads gets you new everything for about an hour of work per side. Front rotor is 305mm × 26mm vented, and the caliper bracket bolts torque to 66–85 ft-lbs.
This is the most common DIY job on the WJ and the one that absolutely has to be done correctly — brakes are safety-critical, period. The factory rotor is undersized for the truck's weight, and pad life on stock pads is 30–40k miles. By the time you're doing this job, the rotors are usually scored and warped enough to make resurfacing pointless. Buy new rotors.
A note on caliper history: WJs built **through May 10, 2002** use Teves calipers. WJs built **after May 11, 2002** use Akebono "fully-closed" style calipers. The pad and bracket geometry is different between the two. If you're replacing a caliper, check the build date plate on the driver door jamb to be sure you get the right one. Pads are largely interchangeable between the two but kit number 5093183AA is the revised pad that fits both.
Loosen the lug nuts (19mm) before lifting. Jack the front, set on stands, pull wheels. Behind the rotor, the caliper bracket has two big 15mm bolts (some are 18mm — check yours). Pull the whole caliper-and-bracket assembly off as one unit — hang it from the coil spring with a bungee, never let it dangle on the rubber line. The rotor slides off the hub once the caliper is out of the way (sometimes it needs a few hammer taps if it's rust-welded).
Push the piston back into the caliper with a C-clamp — open the bleeder first so the old fluid pushes out instead of back up the line. Slide the new pads into the bracket, drop the bracket back over the new rotor, torque the bracket bolts to 76 ft-lbs (middle of the 66–85 range), torque the slide pins to 25 ft-lbs. Wheel on, lug nuts to 95 ft-lbs.
Before driving — pump the brake pedal multiple times to push the piston back out against the new pads. The first pedal will go to the floor if you skip this. Bed the pads in with 8–10 moderate stops from 35 mph, then let them cool.
| Part | Vendor | Est. price |
|---|---|---|
| Mopar front rotor (each) | Mopar | ~$65 |
| Mopar front pad kit | Mopar | ~$90 |
| Centric Premium rotor (aftermarket) | Centric / PartsGeek | ~$35 |
| Akebono ProACT ceramic pads | Akebono | ~$55 |
Written and maintained by an AZ wheeler and driveway wrencher. Always cross-reference your factory service manual — modifications affect vehicle safety and warranty. Work at your own risk.