Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Jeep Cherokee XJ 1997.1999-2001 Approved 2000 XJ Jeep Cherokee exj_5
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XJ BRAKES 5-1
BRAKES
TABLE OF CONTENTS
page page
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1 ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . . . 33
BASE BRAKE SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 2 COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 16
SERVICE WARNINGS & CAUTIONS . . . . . . . . . . . 2 MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 16
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 17
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 2 FRONT DISC BRAKE CALIPER . . . . . . . . . . . . . . 18
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . . 3 FRONT DISC BRAKE SHOES . . . . . . . . . . . . . . . 20
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . . 3 DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 21
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 3 DRUM BRAKE SHOES. . . . . . . . . . . . . . . . . . . . . 21
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . . 3 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT DISC BRAKES. . . . . . . . . . . . . . . . . . . . . . 4 BRAKE SUPPORT PLATE . . . . . . . . . . . . . . . . . . 22
REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . . 5 REAR PARKING BRAKE CABLES . . . . . . . . . . . . 23
PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . 5 PARKING BRAKE LEVER. . . . . . . . . . . . . . . . . . . 23
BRAKE HOSES AND LINES . . . . . . . . . . . . . . . . . . 7 DISASSEMBLY AND ASSEMBLY
DIAGNOSIS AND TESTING MASTER CYLINDER RESERVOIR . . . . . . . . . . . . 24
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . 7 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . 25
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 9 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 28
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . . 9 CLEANING AND INSPECTION
MASTER CYLINDER/POWER BOOSTER . . . . . . . 10 CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 11 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 29
DISC BRAKE ROTOR. . . . . . . . . . . . . . . . . . . . . . 11 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 29
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ADJUSTMENTS
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . . . 12 BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 30
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . . 12 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 30
SERVICE PROCEDURES PARKING BRAKE CABLE TENSIONER . . . . . . . . 31
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . 12 SPECIFICATIONS
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 12 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BASE BRAKE BLEEDING. . . . . . . . . . . . . . . . . . . 13 BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . . . 32
DISC ROTOR MACHINING. . . . . . . . . . . . . . . . . . 13 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 32
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . . 14 SPECIAL TOOLS
BRAKE TUBE FLARING . . . . . . . . . . . . . . . . . . . . 14 BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL AND INSTALLATION
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 15
5-2 BRAKES XJ
DESCRIPTION AND OPERATION CAUTION: Never use gasoline, kerosene, alcohol,
motor oil, transmission fluid, or any fluid containing
BRAKE SYSTEM mineral oil to clean the system components. These
fluids damage rubber cups and seals. Use only
DESCRIPTION fresh brake fluid or Mopar brake cleaner to clean or
Power assist front disc and rear drum brakes are flush brake system components. These are the only
standard equipment. Disc brake components consist cleaning materials recommended. If system contam-
of single piston calipers and ventilated rotors. Rear ination is suspected, check the fluid for dirt, discol-
drum brakes are dual shoe units with cast brake oration, or separation into distinct layers. Also
drums. check the reservoir cap seal for distortion. Drain
The parking brake mechanism is lever and cable and flush the system with new brake fluid if con-
operated. The cables are attached to levers on the tamination is suspected.
rear drum brake secondary shoes. The parking
brakes are operated by a hand lever. CAUTION: Use Mopar brake fluid, or an equivalent
A dual diaphragm vacuum power brake booster is quality fluid meeting SAE/DOT standards J1703 and
used for all applications. All models have an alumi- DOT 3. Brake fluid must be clean and free of con-
num master cylinder with plastic reservoir. taminants. Use fresh fluid from sealed containers
All models are equipped with a combination valve. only to ensure proper antilock component opera-
The valve contains a pressure differential valve and tion.
switch and a fixed rate rear proportioning valve.
Factory brake lining on all models consists of an
organic base material combined with metallic parti- CAUTION: Use Mopar multi-mileage or high temper-
cles. The original equipment linings do not contain ature grease to lubricate caliper slide surfaces,
asbestos. drum brake pivot pins, and shoe contact points on
the backing plates. Use multi-mileage grease or GE
SERVICE WARNINGS & CAUTIONS 661 or Dow 111 silicone grease on caliper slide pins
to ensure proper operation.
DESCRIPTION
WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PEDAL
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM AFTERMARKET DESCRIPTION
LININGS. BREATHING EXCESSIVE CONCENTRA- A suspended-type brake pedal is used, the pedal
TIONS OF ASBESTOS FIBERS CAN CAUSE SERI- pivots on a shaft mounted in the pedal support
OUS BODILY HARM. EXERCISE CARE WHEN bracket. The bracket is attached to the dash panel
SERVICING BRAKE PARTS. DO NOT CLEAN and steering support bracket. The unit is serviced as
BRAKE PARTS WITH COMPRESSED AIR OR BY an assembly, except for the pedal pad.
DRY BRUSHING. USE A VACUUM CLEANER SPE-
CIFICALLY DESIGNED FOR THE REMOVAL OF OPERATION
ASBESTOS FIBERS FROM BRAKE COMPONENTS. The brake pedal is attached to the booster push
IF A SUITABLE VACUUM CLEANER IS NOT AVAIL- rod. When the pedal is depressed, the primary
ABLE, CLEANING SHOULD BE DONE WITH A booster push rod is depressed which move the booster
WATER DAMPENED CLOTH. DO NOT SAND, OR secondary rod. The booster secondary rod depress the
GRIND BRAKE LINING UNLESS EQUIPMENT USED master cylinder piston.
IS DESIGNED TO CONTAIN THE DUST RESIDUE.
DISPOSE OF ALL RESIDUE CONTAINING ASBES- BRAKE LAMP SWITCH
TOS FIBERS IN SEALED BAGS OR CONTAINERS
TO MINIMIZE EXPOSURE TO YOURSELF AND OTH- DESCRIPTION
ERS. FOLLOW PRACTICES PRESCRIBED BY THE The plunger type brake lamp switch is mounted on
OCCUPATIONAL SAFETY AND HEALTH ADMINIS- a bracket attached to the brake pedal support. The
TRATION AND THE ENVIRONMENTAL PROTECTION switch can be adjusted when necessary.
AGENCY FOR THE HANDLING, PROCESSING, AND
DISPOSITION OF DUST OR DEBRIS THAT MAY OPERATION
CONTAIN ASBESTOS FIBERS. The brake lamp switch is used to for the brake
lamp, speed control and brake sensor circuits.
XJ BRAKES 5-3
DESCRIPTION AND OPERATION (Continued)
RED BRAKE WARNING LAMP MASTER CYLINDER
DESCRIPTION DESCRIPTION
A red warning lamp is used for the service brake The master cylinder has a removable nylon reser-
portion of the hydraulic system. The lamp is located voir. The cylinder body is made of aluminum and
in the instrument cluster. contains a primary and secondary piston assembly.
The cylinder body including the piston assemblies
OPERATION are not serviceable. If diagnosis indicates an internal
The red warning light alerts the driver if a pres- problem with the cylinder body, it must be replaced
sure differential exists between the front and rear as an assembly. The reservoir and grommets are the
hydraulic systems or the parking brakes are applied. only replaceable parts on the master cylinder.
The lamp is turned on momentarily when the igni-
tion switch is turn to the on position. This is a self OPERATION
test to verify the lamp is operational. The master cylinder bore contains a primary and
secondary piston. The primary piston supplies
POWER BRAKE BOOSTER hydraulic pressure to the front brakes. The secondary
piston supplies hydraulic pressure to the rear brakes.
DESCRIPTION The master cylinder reservoir stores reserve brake
The booster assembly consists of a housing divided fluid for the hydraulic brake circuits.
into separate chambers by two internal diaphragms.
The outer edge of each diaphragm is attached to the COMBINATION VALVE
booster housing. The diaphragms are connected to
the booster primary push rod. DESCRIPTION
Two push rods are used in the booster. The pri- The combination valve contains a pressure differ-
mary push rod connects the booster to the brake ential valve and switch and a rear brake proportion-
pedal. The secondary push rod connects the booster ing valve. The valve is not repairable and must be
to the master cylinder to stroke the cylinder pistons. replaced as an assembly if diagnosis indicates this is
necessary.
OPERATION
The atmospheric inlet valve is opened and closed OPERATION
by the primary push rod. Booster vacuum supply is
through a hose attached to an intake manifold fitting PRESSURE DIFFERENTIAL VALVE
at one end and to the booster check valve at the The pressure differential switch is connected to the
other. The vacuum check valve in the booster housing brake warning light. The switch is actuated by move-
is a one-way device that prevents vacuum leak back. ment of the switch valve. The switch monitors fluid
Power assist is generated by utilizing the pressure pressure in the separate front/rear brake hydraulic
differential between normal atmospheric pressure circuits.
and a vacuum. The vacuum needed for booster oper- A decrease or loss of fluid pressure in either
ation is taken directly from the engine intake mani- hydraulic circuit will cause the switch valve to shut-
fold. The entry point for atmospheric pressure is tle to the low pressure side. Movement of the valve
through a filter and inlet valve at the rear of the pushes the switch plunger upward. This action closes
housing (Fig. 1). the switch internal contacts completing the electrical
The chamber areas forward of the booster dia- circuit to the red warning light. The switch valve will
phragms are exposed to vacuum from the intake remain in an actuated position until repairs to the
manifold. The chamber areas to the rear of the dia- brake system are made.
phragms, are exposed to normal atmospheric pres-
sure of 101.3 kilopascals (14.7 pounds/square in.). PROPORTIONING VALVE
Brake pedal application causes the primary push The proportioning valve is used to balance front-
rod to open the atmospheric inlet valve. This exposes rear brake action at high decelerations. The valve
the area behind the diaphragms to atmospheric pres- allows normal fluid flow during moderate braking.
sure. The resulting pressure differential provides the The valve only controls fluid flow during high decel-
extra apply force for power assist. erations brake stops.
The booster check valve, check valve grommet and
booster seals are serviceable.
5-4 BRAKES XJ
DESCRIPTION AND OPERATION (Continued)
Fig. 1 Power Brake Booster◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo