[CJ-John]

Well the time has come! I blew out a rear brake line on my 98 Sahara. Now the ABS never has worked in the three years I've owned it and I knew when I bought it that all the brake lines were severely rusted so it was only a matter of time before the first one would blow. Now my plan has always been to simply remove the under hood unit and redo the lines without it. I guess my question is has anyone here done this and what surprises might I run into? I already removed the front toner rings, and the light bulb in the dash. any thoughts? Thanks, John

 

[Jerry Bransford]

Personally, I'd leave the ABS pump in place and simply replace the bad brake line. Removing the ABS pump would entail replacing all the brake lines which to me, would be a PITA not worth the effort for the zero benefit returned. When disabled, the ABS pump's presence does not affect braking in the least.

 

[CJ-John]

I still have that option but if it's non functional and just taking up space I thought I'd do away with it and the extra lines. I have to replace all the lines anyway as they are in horrible condition and I am going to buy a complete kit anyway. I still have to call the company that makes the kit and see what they have for options.

 

[Hammond_Egger]

I am getting ready to do this myself. All of my lines have chunks of rust on them..
and I have a low mileage set of rears without ABS (I know I can move over the knuckles/axles, but my stuff is rusted up!).

I bought the Classic Tube stainless steel prebent kit from Quadratec:
Classic Tube JE1043 - Classic Tube Pre-Formed Stainless Steel Brake Line Kit for 97-06 Jeep® Wrangler TJ with Rear Drum Brakes & without ABS - Quadratec

So far, the info I gathered (from this and other forums):

Remove the following:
A) In the PDC:
1) ABS Pump Relay (#30)
2) ABS Relay (#33)
3) 10A ABS Mod Fuse (#28)
4) ABS Pump Fuse (#6)
5) ABS System Fuse (#7)

B) The ABS Controller under the dash (2 connectors)

You will need the brakeline adapter that screws into the distro block (currently has a plug where the rear brakeline will go). I pulled one from the junkyard.

Of course, remove the ABS sensors from each wheel.

If you do it first, let me know what you did..If I do it before you, I will let you know!

 

[CJ-John]

I am getting ready to do this myself. All of my lines have chunks of rust on them..
and I have a low mileage set of rears without ABS (I know I can move over the knuckles/axles, but my stuff is rusted up!).

I bought the Classic Tube stainless steel prebent kit from Quadratec:
Classic Tube JE1043 - Classic Tube Pre-Formed Stainless Steel Brake Line Kit for 97-06 Jeep® Wrangler TJ with Rear Drum Brakes & without ABS - Quadratec

So far, the info I gathered (from this and other forums):

Remove the following:
A) In the PDC:
1) ABS Pump Relay (#30)
2) ABS Relay (#33)
3) 10A ABS Mod Fuse (#28)
4) ABS Pump Fuse (#6)
5) ABS System Fuse (#7)

B) The ABS Controller under the dash (2 connectors)

You will need the brakeline adapter that screws into the distro block (currently has a plug where the rear brakeline will go). I pulled one from the junkyard.

Of course, remove the ABS sensors from each wheel.

If you do it first, let me know what you did..If I do it before you, I will let you know!

I also see that the proportioning valve goes to the ABS pump with one line for the front. So we are going to need to split that before it heads to both front wheels. I'm not sure the junk yards around here have any TJ's in them. And yes I'm doing the project this week as it's my DD and it's down. Thanks, John

 

[CJ-John]

Well I dove right in! I have all the old lines off, A new complete kit coming from classic tube, and now I'll start pulling the abs unit from under the hood. can anyone send me a clear picture of the master cylinder area of a non ABS setup. They told me 97 - 06 are all the same kit. so any TJ would do. maybe someone has a jeep sitting without the motor or front sheet metal that would make the picture easier. Both the master cylinder and proportioning valves have different part numbers for ABS and non ABS but we'll soon find out if there really much difference. I'll give progress reports as I go. Thank, John

 

[50Johnbob]

Let me know if you need something more specific

 

[CJ-John]

Thanks, 50Johnbob I can see that the 2nd line for the front comes right off the back of the proportioning valve. I'll see if the plug that I have there will come out and be replaced with a threaded bushing to fit the passenger front line.

 

[2002TJ]

Here's another from driver's side fender lookin toward passenger side...2002 TJ

Tried to get closeup from engine compartment showing master and block, but phone battery crapped out

 

[2002TJ]

Here's engine bay side...once again it's a 2002 TJ

 

[CJ-John]

Ordered the line kit Monday morning, it arrived Tuesday afternoon! Now that's service! I'm out of town so I'll get to it on the weekend.

 

[CJ-John]

Well so far I have all the rear lines on. not a bad job. going to pick a part today to get adapter fitting for front line to proportioning valve. It looks like the real pain in the a** will be the passenger front line but we'll see how that goes, I may unbolt the mount below the Red. and the plastic shield over the front sway bay and see where that gets me.

 

[crallscars]

My 97 doesn't have ABS, when did they start putting it back in Jeeps? or was it an option?

 

[CJ-John]

My 97 doesn't have ABS, when did they start putting it back in Jeeps? or was it an option?

I believe it was an option,
Now on my progress. I gave up on the passenger front and started pulling the front sheet metal off. I could see no way that the line was going in one piece without the fenders and grill being off. It will set me back a couple of days but it will be done right!

 

[CJ-John]

The front clip came off the lines went on easily then time to clean up and put it back together. This was the way to do the front all due to the routing of the right front line. maybe some pictures today.

 

[Hammond_Egger]

Hmm, I was thinking of just taking off the front bumper to do the pass side.
Did you break any of the plastic clips?

 

[CJ-John]

Yes most of the clip shattered when i tried to open them so I'll use metal ones I had from another project. Also I'm not sure taking the front bumper off will help that much but it might.

 

[Hammond_Egger]

Let me know if you cannot find the fitting for the rear brake line. There are a few wranglers in the pick and pull by me (picked pretty clean, but they still have what you need!

I am hoping that pulling the front bumper and sway bar should do it...no way I want to pull the front clip (not wanting to remove my AC condenser!)

I have working in some pretty tight spots before

 

[CJ-John]

Job is done, brakes work as they should, it was not a big deal pulling the front clip - I would do it that way again. overall a successful project.

 

[tagrav]

I am going to be doing this to my girlfriends jeep and this is the first time i've gotten a pic of how that front line routes. Can this be done without removing the front clip or the bumper?

I would really like to avoid removing as much as possible. I am also using copper nickle line as it holds up much better than standard steel lines. I will be making my own brake lines for this job.