Jeep Cherokee (XJ): Removal and installation

Brake lamp switch

REMOVAL

(1) Remove steering column cover and lower trim panel for switch access (if necessary).

(2) Press brake pedal downward to fully applied position.

(3) Rotate switch approximately 30 in counterclockwise direction to unlock switch retainer. Then pull switch rearward and out of bracket.

(4) Disconnect switch harness and remove switch from vehicle (Fig. 17).

Fig. 17 Brake Lamp Switch
Fig. 17 Brake Lamp Switch

1 - SWITCH
2 - HARNESS CONNECTOR

INSTALLATION

(1) Pull switch plunger all the way out to fully extended position.

(2) Connect harness wires to switch.

(3) Press and hold brake pedal in applied position.

(4) Install switch as follows: Align tab on switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30 to lock it in place.

(5) Release brake pedal. Then pull pedal lightly rearward. Pedal will set plunger to correct position as pedal pushes plunger into switch body. Switch will make ratcheting sound as it self adjusts.

CAUTION: Booster damage may occur if the pedal pull exceeds 20 lbs..

Brake pedal

REMOVAL

(1) Remove knee blocker under the steering column.

(2) Remove retainer clip securing booster push rod to pedal (Fig. 18).

(3) Remove brake lamp switch.

(4) Remove nuts securing the booster to the pedal support bracket and nuts to the column bracket.

(5) Remove pedal and support bracket as an assembly from the vehicle.

Fig. 18 Booster Push Rod
Fig. 18 Booster Push Rod

1 - BRAKE PEDAL
2 - BOOSTER ROD
3 - BUSHING

INSTALLATION

(1) Install pedal and support bracket as an assembly into the vehicle.

(2) Install nuts securing the booster to the pedal support bracket and nuts to the column bracket.

(3) Tighten nuts to 39 N·m (29 ft. lbs.).

(4) Lubricate the brake pedal pin and bushings with Mopar multi-mileage grease.

(5) Install booster push rod on pedal pin and install new retainer clip.

(6) Install knee blocker.

Combination valve

NOTE: The combination valve is not repairable. The valve is serviced as an assembly only.

REMOVAL

(1) Remove air cleaner cover and hose for access to valve.

(2) Unsnap connector lock tabs and disconnect differential pressure switch wire at combination valve (Fig. 19). Do not pull switch wire to disconnect.

(3) Disconnect brake lines at combination valve (Fig. 20).

(4) Remove mounting nut and remove valve.

INSTALLATION

(1) Install valve and tighten mounting nut to 17 N·m (155 in. lbs.).

(2) Connect brake lines to replacement valve. Start line fittings by hand to avoid cross threading.

(3) Tighten brake line fittings to 14 N·m (124 in.

lbs.).

Fig. 19 Differential Pressure Switch
Fig. 19 Differential Pressure Switch

1 - SWITCH TERMINAL
2 - COMBINATION VALVE
3 - WIRE HARNESS CONNECTOR

Fig. 20 Combination Valve
Fig. 20 Combination Valve

1 - COMBINATION VALVE
2 - MASTER CYLINDER

(4) Connect wire to pressure differential switch.

(5) Bleed base brakes.

Master cylinder

REMOVAL

(1) Remove brake lines at master cylinder and combination valve (Fig. 20).

(2) Disconnect differential pressure switch wire from the combination valve.

(3) Remove mounting nuts from the combination valve bracket and remove the valve (Fig. 20).

(4) Remove mounting nuts from the master cylinder (Fig. 21).

(5) Remove master cylinder.

(6) Remove cylinder cover and drain fluid.

(7) If master cylinder reservoir requires service, refer to reservoir replacement procedure in this section.

Fig. 21 Master Cylinder
Fig. 21 Master Cylinder

1 - BOOSTER
2 - MASTER CYLINDER

INSTALLATION

NOTE: If master cylinder is replaced, bleed cylinder before installation.

(1) Remove protective sleeve from primary piston shank on new master cylinder.

(2) Clean cylinder mounting surface of brake booster.

(3) Install master cylinder onto brake booster studs.

(4) Install mounting nuts and tighten to 17 N·m (155 in. lbs.).

(5) Install combination valve and install mounting nuts.

(6) Connect brake lines to master cylinder and combination valve and tighten to 14 N·m (124 in.

lbs.).

(7) Connect differential pressure switch wire to the combination valve.

(8) On RHD vehicles install the coolant reserve/ overflow tank. Refer to Group 7 Cooling System.

(9) Fill and bleed base brake system.

Power brake booster

REMOVAL

(1) On RHD vehicles remove the coolant reserve/ overflow tank. Refer to Group 7 Cooling System.

(2) Disconnect brake lines at master cylinder.

(3) Disconnect wire at combination valve differential pressure switch.

(4) Remove nut mounting combination valve bracket to booster studs and remove valve.

(5) Remove nuts mounting master cylinder to booster studs and remove cylinder.

(6) Disconnect vacuum hose from booster check valve.

(7) Remove knee blocker under the steering column.

(8) Remove retaining clip that secures booster push rod to brake pedal (Fig. 22).

(9) Remove nuts attaching booster to passenger compartment side of dash panel (Fig. 23).

Fig. 22 Booster Push Rod
Fig. 22 Booster Push Rod

1 - BRAKE PEDAL
2 - BOOSTER ROD
3 - BUSHING

(10) In engine compartment, slide booster studs out of dash panel, tilt booster upward, and remove booster from engine compartment.

(11) Remove dash seal from booster.

INSTALLATION

(1) Install dash seal on booster.

(2) Align and position booster on dash panel.

(3) In passenger compartment, install booster mounting nuts. Tighten nuts just enough to hold booster in place.

(4) Slide booster push rod onto the brake pedal.

Then secure push rod to pedal pin with retaining clip.

Fig. 23 Booster Mounting
Fig. 23 Booster Mounting

1 - BOOSTER

NOTE: Lubricate the pedal pin and bushing with Mopar multi-mileage grease before installation.

(5) Tighten booster mounting nuts to 39 N·m (29 ft. lbs.).

(6) Install the knee blocker.

(7) If original master cylinder is being installed, check condition of seal at rear of master cylinder.

Replace seal if cut, or torn.

(8) Clean cylinder mounting surface of brake booster. Use shop towel wetted with brake cleaner for this purpose. Dirt, grease, or similar materials will prevent proper cylinder seating and could result in vacuum leak.

(9) Align and install master cylinder on booster studs. Install mounting nuts and tighten to 17.5 N·m (155 in. lbs.).

(10) Connect vacuum hose to booster check valve.

(11) Connect and secure brake lines to combination valve and master cylinder. Start all brake line fittings by hand to avoid cross threading.

(12) Install combination valve on booster studs.

Tighten bracket mounting nuts to 17.5 N·m (155 in.

lbs.).

(13) Connect wire to combination valve switch.

(14) On RHD vehicles install the coolant reserve/ overflow tank. Refer to Group 7 Cooling System.

(15) Fill and bleed base brake system.

(16) Verify proper brake operation before moving vehicle.

Front disc brake caliper

REMOVAL

(1) Raise and support vehicle.

(2) Remove front wheel and tire assembly.

(3) Drain small amount of fluid from master cylinder brake reservoir with suction gun.

(4) Bottom caliper piston in bore with C-clamp.

Position clamp screw on outboard brake shoe and clamp frame on rear of caliper (Fig. 24). Do not allow clamp screw to bear directly on outboard shoe retainer spring. Use wood or metal spacer between shoe and clamp screw.

Fig. 24 Bottoming Caliper Piston With C-Clamp
Fig. 24 Bottoming Caliper Piston With C-Clamp

1 - CALIPER BOSS
2 - OUTBOARD BRAKESHOE
3 - C-CLAMP

(5) Remove brake hose mounting bolt and discard washers (Fig. 25).

Fig. 25 Brake Hose And BoltБЮ Fig. 25 Brake Hose And Bolt

1 - FITTING WASHERS
2 - CALIPERS

(6) Remove caliper mounting bolts (Fig. 26).

Fig. 26 Caliper Mounting Bolts
Fig. 26 Caliper Mounting Bolts

1 - CALIPER MOUNTING BOLT (2)
2 - CALIPER

(7) Tilt top of caliper outward with pry tool if necessary (Fig. 27) and remove caliper

Fig. 27 Caliper Removal
Fig. 27 Caliper Removal

1 - TILT CALIPER OUTBOARD TO REMOVE

(8) Remove caliper from vehicle

INSTALLATION

(1) Clean brake shoe mounting ledges with wire brush and apply light coat of Mopar multi-mileage grease to surfaces (Fig. 28).

(2) Install caliper by position notches at lower end of brake shoes on bottom mounting ledge. Then rotate caliper over rotor and seat notches at upper end of shoes on top mounting ledge (Fig. 29).

(3) Coat caliper mounting bolts with silicone grease. Then install and tighten bolts to 15 N·m (11 ft. lbs.).

CAUTION: If new caliper bolts are being installed, or if the original reason for repair was a drag/pull condition, check caliper bolt length before proceeding.

Bolts must not have a shank length greater than 67.6 mm (2.66 in.) (Fig. 30).

Fig. 28 Caliper Lubrication Points
Fig. 28 Caliper Lubrication Points

1 - BUSHINGS
2 - CALIPER MOUNTING BOLTS
3 - MOUNTING LEDGES

Fig. 29 Caliper Installation
Fig. 29 Caliper Installation

1 - TOP LEDGE
2 - BRAKESHOE TAB ON LEDGE OUTER SURFACE
3 - LEDGE SEATED IN BRAKESHOE NOTCH
4 - BOTTOM LEDGE

(4) Install brake hose to caliper with new seal washers and tighten fitting bolt to 31 N·m (23 ft.

lbs.).

Fig. 30 Mounting Bolt Dimensions
Fig. 30 Mounting Bolt Dimensions

1 - 67 mm (6 0.6 mm) 2.637 in. (6 0.0236 in.)
2 - 22 mm (0.866 in.) THREAD LENGTH
3 - CALIPER BOLT

CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt.

(5) Bleed base brake system.

(6) Install wheel and tire assemblies.

(7) Remove supports and lower vehicle.

(8) Verify firm pedal before moving vehicle.

Front disc brake shoes

REMOVAL

(1) Raise and support vehicle.

(2) Remove wheel and tire assembly.

(3) Remove caliper.

(4) Pressing one end of outboard shoe inward to disengage shoe lug. Then rotate shoe upward until retainer spring clears caliper. Press opposite end of shoe inward to disengage shoe lug and rotate shoe up and out of caliper (Fig. 31).

(5) Grasp ends of inboard shoe and tilt shoe outward to release springs from caliper piston (Fig. 32) and remove shoe from caliper.

NOTE: If original brake shoes will be used, keep them in sets left and right. They are not interchangeable.

(6) Secure caliper to nearby suspension part with wire. Do not allow brake hose to support caliper weight.

(7) Wipe caliper off with shop rags or towels.

CAUTION: Do not use compressed air, this can unseat dust boot and force dirt into piston bore.

Fig. 31 Outboard Brake Shoe Removal
Fig. 31 Outboard Brake Shoe Removal

1 - OUTBOARD BRAKESHOE
2 - SHOE SPRING
3 - LOCATING LUG
4 - CALIPER
5 - LOCATING LUG

Fig. 32 Inboard Brake Shoe Removal
Fig. 32 Inboard Brake Shoe Removal

1 - CALIPER PISTON
2 - SHOE SPRINGS
3 - INBOARD BRAKESHOE

INSTALLATION

(1) Install inboard shoe in caliper and verify shoe retaining is fully seated into the piston.

(2) Starting one end of outboard shoe in caliper and rotating shoe downward into place. Verify shoe locating lugs and shoe spring are seated.

(3) Install caliper.

(4) Install wheel and tire assembly.

(5) Remove support and lower vehicle.

(6) Pump brake pedal until caliper pistons and brake shoes are seated.

(7) Top off brake fluid level if necessary.

Disc brake rotor

REMOVAL

(1) Remove wheel and tire assemble.

(2) Remove caliper.

(3) Remove retainers securing rotor to hub studs (Fig. 33).

(4) Remove rotor from hub.

(5) If rotor shield requires service, remove front hub and bearing assembly.

Fig. 33 Rotor & Hub
Fig. 33 Rotor & Hub

1 - ROTOR
2 - RETAINER
3 - BEARING NUT
4 - NUT LOCK
5 - COTTER PIN
6 - WASHER

INSTALLATION

(1) If new rotor is being installed, remove protective coating from rotor surfaces with carburetor cleaner.

(2) Install rotor on hub.

(3) Install caliper.

(4) Install wheel and tire assembly.

Drum brake shoes

REMOVAL

(1) Raise vehicle and remove rear wheels.

(2) Remove and discard spring nuts securing drums to wheel studs.

(3) Remove brake drums. If drums prove difficult to remove, retract brake shoes. Remove access plug at the rear of backing plate and back off adjuster screw with brake tool and screwdriver.

(4) Remove U-clip and washer securing adjuster cable to parking brake lever (Fig. 34).

(5) Remove primary and secondary return springs from anchor pin with brake spring pliers.

(6) Remove hold-down springs, retainers and pins with standard retaining spring tool.

(7) Install spring clamps on wheel cylinders to hold pistons in place.

(8) Remove adjuster lever, adjuster screw and spring.

(9) Remove adjuster cable and cable guide.

(10) Remove brake shoes and parking brake strut.

(11) Disconnect cable from parking brake lever and remove lever.

INSTALLATION

(1) Clean support plate with brake cleaner.

(2) If new drums are being installed, remove protective coating with carburetor cleaner followed by final rinse with brake cleaner.

(3) Clean and lubricate anchor pin with light coat of Mopar multi-mileage grease.

(4) Apply Mopar multi-mileage grease to brake shoe contact surfaces of support plate (Fig. 35).

(5) Lubricate adjuster screw threads and pivot with spray lube.

(6) Attach parking brake lever to secondary brake shoe. Use new washer and U-clip to secure lever.

(7) Remove wheel cylinder clamps.

(8) Attach parking brake cable to lever.

(9) Install brake shoes on support plate. Secure shoes with new hold-down springs, pins and retainers.

(10) Install parking brake strut and spring.

(11) Install guide plate and adjuster cable on anchor pin.

(12) Install primary and secondary return springs.

(13) Install adjuster cable guide on secondary shoe.

(14) Lubricate and assemble adjuster screw.

(15) Install adjuster screw, spring and lever and connect to adjuster cable.

(16) Adjust shoes to drum.

(17) Install wheel/tire assemblies and lower vehicle.

(18) Verify firm brake pedal before moving vehicle.

Wheel cylinder

REMOVAL

(1) Remove wheel and tire assembly.

(2) Remove brake drum.

(3) Disconnect wheel cylinder brake line.

(4) Remove brake shoe return springs and move shoes out of engagement with cylinder push rods.

(5) Remove cylinder attaching bolts and remove cylinder from support plate.

Fig. 34 Drum Brake Components-Typical
Fig. 34 Drum Brake Components-Typical

1 - ADJUSTER LEVER
2 - ADJUSTER CABLE
3 - HOLDDOWN SPRING AND RETAINERS
4 - ADJUSTER LEVER SPRING
5 - TRAILING SHOE
6 - CYLINDER-TO-SUPPORT SEAL
7 - HOLDDOWN PINS
8 - ACCESS PLUGS
9 - SUPPORT PLATE
10 - CABLE HOLE PLUG
11 - PARK BRAKE STRUT AND SPRING
12 - ADJUSTER SCREW ASSEMBLY
13 - HOLDDOWN SPRING AND RETAINERS
14 - LEADING SHOE
15 - CABLE GUIDE
16 - SHOE RETURN SPRINGS
17 - SHOE GUIDE PLATE
18 - PIN
19 - SHOE SPRING
20 - PARK BRAKE LEVER

Fig. 35 Shoe Contact Surfaces
Fig. 35 Shoe Contact Surfaces

1 - ANCHOR PIN
2 - SUPPORT PLATE
3 - SHOE CONTACT SURFACES

INSTALLATION

(1) Apply bead of silicone sealer around cylinder mounting surface of support plate.

(2) Install cylinder mounting bolts and tighten to 20 N·m (15 ft. lbs.).

(3) Connect brake line to cylinder.

(4) Install brake shoe return spring.

(5) Install brake drum.

(6) Install wheel and tire assembly.

(7) Bleed base brake system.

Brake support plate

REMOVAL

(1) Remove wheel and tire assembly and brake drum.

(2) Remove brake shoe assembly.

(3) Remove parking brake cable from parking brake lever.

(4) Compress parking brake cable retainer tabs.

Then push retainer and cable through and out of support plate.

(5) Disconnect brake line at wheel cylinder.

(6) Remove wheel cylinder from support plate.

(7) Remove axle shaft, refer to Group 3 for procedures.

(8) Remove bolts attaching support plate to axle and remove support plate.

INSTALLATION

(1) Apply bead of silicone sealer around axle mounting surface of support plate.

(2) Install support plate on axle flange. Tighten attaching bolts to 115 N·m (85 ft. lbs.).

(3) Apply bead of silicone sealer around wheel cylinder mounting surface and install wheel cylinder.

(4) Install brake line in wheel cylinder.

(5) Install parking brake cable in support plate.

(6) Install axle shaft, refer to Group 3 for procedure.

(7) Connect parking brake cable to lever on secondary shoe and install brake shoes on support plate.

(8) Adjust brake shoes to drum with brake gauge.

(9) Install brake drum and wheel and tire assembly.

(10) Bleed brake system.

Rear parking brake cables

REMOVAL

(1) Raise vehicle and loosen equalizer nuts until rear cables are slack.

(2) Disengage cables from equalizer and compress cable retainers with a worm drive hose clamp.

(3) Remove cables from the cable bracket (Fig. 36).

(4) Remove rear wheel and brake drums.

(5) Remove secondary brake shoe and disconnect cable from lever on brake shoe.

(6) Compress cables retainer with worm drive hose clamp (Fig. 37) and remove cables from backing plates.

INSTALLATION

(1) Install new cables in backing plates. Be sure cable retainer is seated.

(2) Attach cable to lever on brake shoe and install brake shoe on backing plate.

(3) Adjust brake shoes to drum with brake gauge.

(4) Install brake drums and wheels.

(5) Install cables into the cable bracket and insure retainers are seated in the bracket.

(6) Engage the cable ends into the equalizer and install equalizer nut.

(7) Adjust parking brakes.

Fig. 36 Parking Brake Cables
Fig. 36 Parking Brake Cables

1 - REAR CABLES
2 - EQUALIZER
3 - FRONT CABLE
4 - TENSIONER ROD

Fig. 37 Cable Retainer
Fig. 37 Cable Retainer

1 - CABLE RETAINER
2 - REAR CABLE
3 - WORM DRIVE HOSE CLAMP

Parking brake lever

The center console must be removed to service the parking brake lever. Refer to Group 23 Interior Components for service procedures.

REMOVAL

(1) Release parking brakes.

(2) Raise vehicle.

(3) Remove adjusting nut from tensioner rod at the equalizer (Fig. 38).

Fig. 38 Parking Brake Equalizer
Fig. 38 Parking Brake Equalizer

1 - REAR CABLES
2 - EQUALIZER
3 - FRONT CABLE
4 - TENSIONER ROD

(4) Lower vehicle.

(5) Disengage front cable from the cable lever.

(6) Compress cable retainer with worm drive hose clamp and remove the cable from the parking brake lever base.

(7) Disconnect parking brake lamp switch wire (Fig. 39).

(8) Remove parking brake lever assembly mounting bolts (Fig. 39).

(9) Remove lever assembly.

(10) Remove parking brake lamp switch.

INSTALLATION

(1) Install parking brake lamp switch.

(2) Position lever assembly on floorpan and install lever mounting bolts.

(3) Tighten lever mounting bolts to 10 to 14 N·m (7 to 10 ft. lbs.).

(4) Insert front cable through the parking brake lever base. Insure the cable retainer is seated into the base.

(5) Attach the front cable to the cable lever (Fig.

39).

(6) Connect parking brake lamp switch wire.

(7) Raise vehicle.

(8) Install adjusting nut to the tensioner rod and adjust parking brakes.

(9) Lower vehicle.

Fig. 39 Parking Brake Lever Assembly
Fig. 39 Parking Brake Lever Assembly

1 - MOUNTING BOLTS
2 - FRONT CABLE LEVER
3 - PARKING BRAKE SWITCH
4 - PARKING BRAKE LEVER

10) Verify correct parking brake operation.

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