Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Jeep Cherokee XJ 1997.1999-2001 Approved 1999 XJ Jeep Cherokee EXJ_5
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XJ BRAKES 5-1
BRAKES
CONTENTS
page page
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . 1 ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . . 30
BASE BRAKE SYSTEM
INDEX
page page
GENERAL INFORMATION REMOVAL AND INSTALLATION
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 2 STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 14
SERVICE WARNINGS & CAUTIONS . . . . . . . . . . 2 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION AND OPERATION COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . 14
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 15
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 2 POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . 15
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . 2 FRONT DISC BRAKE CALIPER . . . . . . . . . . . . . 16
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 2 FRONT DISC BRAKE SHOES . . . . . . . . . . . . . . 18
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 3 DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 19
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 4 DRUM BRAKE SHOES . . . . . . . . . . . . . . . . . . . . 19
FRONT DISC BRAKES . . . . . . . . . . . . . . . . . . . . . 4 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . 20
REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 5 BRAKE SUPPORT PLATE . . . . . . . . . . . . . . . . . 20
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 5 REAR PARKING BRAKE CABLES . . . . . . . . . . . 21
BRAKE HOSES AND LINES . . . . . . . . . . . . . . . . . 6 PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . . 21
DIAGNOSIS AND TESTING DISASSEMBLY AND ASSEMBLY
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . 6 MASTER CYLINDER RESERVOIR . . . . . . . . . . . 22
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 8 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . 23
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . 8 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . 25
MASTER CYLINDER/POWER BOOSTER . . . . . . . 9 CLEANING AND INSPECTION
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 9 CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 10 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . 26
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . 10 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . 26
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . . 11 ADJUSTMENTS
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . 11 STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 26
SERVICE PROCEDURES REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . 27
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . 11 PARKING BRAKE CABLE TENSIONER . . . . . . . 28
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 11 SPECIFICATIONS
BASE BRAKE BLEEDING . . . . . . . . . . . . . . . . . . 12 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DISC ROTOR MACHINING . . . . . . . . . . . . . . . . . 12 BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . . 29
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . 12 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 29
BRAKE TUBE FLARING . . . . . . . . . . . . . . . . . . . 13 SPECIAL TOOLS
BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5-2 BRAKES XJ
GENERAL INFORMATION flush brake system components. These are the only
cleaning materials recommended. If system contam-
BRAKE SYSTEM ination is suspected, check the fluid for dirt, discol-
Power assist front disc and rear drum brakes are oration, or separation into distinct layers. Also
standard equipment. Disc brake components consist of check the reservoir cap seal for distortion. Drain
single piston calipers and ventilated rotors. Rear drum and flush the system with new brake fluid if con-
brakes are dual shoe units with cast brake drums. tamination is suspected.
The parking brake mechanism is lever and cable
operated. The cables are attached to levers on the CAUTION: Use Mopar brake fluid, or an equivalent
rear drum brake secondary shoes. The parking quality fluid meeting SAE/DOT standards J1703 and
brakes are operated by a hand lever. DOT 3. Brake fluid must be clean and free of con-
A dual diaphragm vacuum power brake booster is taminants. Use fresh fluid from sealed containers
used for all applications. All models have an alumi- only to ensure proper antilock component opera-
num master cylinder with plastic reservoir. tion.
All models are equipped with a combination valve.
The valve contains a pressure differential valve and
switch and a fixed rate rear proportioning valve. CAUTION: Use Mopar multi-mileage or high temper-
Factory brake lining on all models consists of an ature grease to lubricate caliper slide surfaces,
organic base material combined with metallic parti- drum brake pivot pins, and shoe contact points on
cles. The original equipment linings do not contain the backing plates. Use multi-mileage grease or GE
asbestos. 661 or Dow 111 silicone grease on caliper slide pins
to ensure proper operation.
SERVICE WARNINGS & CAUTIONS
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON- DESCRIPTION AND OPERATION
TAIN ASBESTOS FIBERS FROM AFTERMARKET
LININGS. BREATHING EXCESSIVE CONCENTRA- BRAKE PEDAL
TIONS OF ASBESTOS FIBERS CAN CAUSE SERI- A suspended-type brake pedal is used, the pedal
OUS BODILY HARM. EXERCISE CARE WHEN pivots on a shaft mounted in the pedal support
SERVICING BRAKE PARTS. DO NOT CLEAN bracket. The bracket is attached to the dash panel
BRAKE PARTS WITH COMPRESSED AIR OR BY and steering support bracket. The unit is serviced as
DRY BRUSHING. USE A VACUUM CLEANER SPE- an assembly, except for the pedal pad.
CIFICALLY DESIGNED FOR THE REMOVAL OF
ASBESTOS FIBERS FROM BRAKE COMPONENTS. STOP LAMP SWITCH
IF A SUITABLE VACUUM CLEANER IS NOT AVAIL- The plunger type stop lamp switch is mounted on a
ABLE, CLEANING SHOULD BE DONE WITH A bracket attached to the brake pedal support. The
WATER DAMPENED CLOTH. DO NOT SAND, OR switch can be adjusted when necessary.
GRIND BRAKE LINING UNLESS EQUIPMENT USED
IS DESIGNED TO CONTAIN THE DUST RESIDUE. RED BRAKE WARNING LAMP
DISPOSE OF ALL RESIDUE CONTAINING ASBES- A red warning lamp is used for the service brake
TOS FIBERS IN SEALED BAGS OR CONTAINERS portion of the hydraulic system. The lamp is located
TO MINIMIZE EXPOSURE TO YOURSELF AND OTH- in the instrument cluster. The red warning light
ERS. FOLLOW PRACTICES PRESCRIBED BY THE alerts the driver if a pressure differential exists
OCCUPATIONAL SAFETY AND HEALTH ADMINIS- between the front and rear hydraulic systems or the
TRATION AND THE ENVIRONMENTAL PROTECTION parking brakes are applied.
AGENCY FOR THE HANDLING, PROCESSING, AND The lamp is turned on momentarily when the igni-
DISPOSITION OF DUST OR DEBRIS THAT MAY tion switch is turn to the on position. This is a self
CONTAIN ASBESTOS FIBERS. test to verify the lamp is operational.
POWER BRAKE BOOSTER
CAUTION: Never use gasoline, kerosene, alcohol, The booster assembly consists of a housing divided
motor oil, transmission fluid, or any fluid containing into separate chambers by two internal diaphragms.
mineral oil to clean the system components. These The outer edge of each diaphragm is attached to the
fluids damage rubber cups and seals. Use only booster housing. The diaphragms are connected to
fresh brake fluid or Mopar brake cleaner to clean or the booster primary push rod.
XJ BRAKES 5-3
DESCRIPTION AND OPERATION (Continued)
Two push rods are used in the booster. The pri- The chamber areas forward of the booster dia-
mary push rod connects the booster to the brake phragms are exposed to vacuum from the intake
pedal. The secondary push rod connects the booster manifold. The chamber areas to the rear of the dia-
to the master cylinder to stroke the cylinder pistons. phragms, are exposed to normal atmospheric pres-
The atmospheric inlet valve is opened and closed sure of 101.3 kilopascals (14.7 pounds/square in.).
by the primary push rod. Booster vacuum supply is Brake pedal application causes the primary push
through a hose attached to an intake manifold fitting rod to open the atmospheric inlet valve. This exposes
at one end and to the booster check valve at the the area behind the diaphragms to atmospheric pres-
other. The vacuum check valve in the booster housing sure. The resulting pressure differential provides the
is a one-way device that prevents vacuum leak back. extra apply force for power assist.
Power assist is generated by utilizing the pressure
differential between normal atmospheric pressure MASTER CYLINDER
and a vacuum. The vacuum needed for booster oper- The master cylinder has a removable nylon reser-
ation is taken directly from the engine intake mani- voir. The cylinder body is made of aluminum and
fold. The entry point for atmospheric pressure is contains a primary and secondary piston assembly.
through a filter and inlet valve at the rear of the The cylinder body including the piston assemblies
housing (Fig. 1). are not serviceable. If diagnosis indicates an internal
problem with the cylinder body, it must be replaced
Fig. 1 Power Brake Booster◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo