sus JEEP GRAND CHEROKEE 2002 WJ / 2.G Owner's Guide

NOTE: The front outer brake shoes are equipped
with a wear indicator. The indicator will produce an
audible noise when it contacts the rotor surface.
BRAKE CHATTER
Brake chatter is usually caused by loose or worn
components, or glazed/burnt lining. Rotors with hard
spots can also contribute to chatter. Additional causes
of chatter are out-of-tolerance rotors, brake lining not
securely attached to the shoes, loose wheel bearings
and contaminated brake lining.
THUMP/CLUNK NOISE
Thumping or clunk noises during braking are fre-
quentlynotcaused by brake components. In many
cases, such noises are caused by loose or damaged
steering, suspension, or engine components.
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL BLEEDING
Use Mopar brake fluid, or an equivalent quality
fluid meeting SAE J1703-F and DOT 3 standards
only. Use fresh, clean fluid from a sealed container at
all times.
Do not pump the brake pedal at any time while
bleeding. Air in the system will be compressed into
small bubbles that are distributed throughout the
hydraulic system. This will make additional bleeding
operations necessary.
Do not allow the master cylinder to run out of fluid
during bleed operations. An empty cylinder will allow
additional air to be drawn into the system. Check the
cylinder fluid level frequently and add fluid as
needed.
Bleed only one brake component at a time in the
following sequence:
(1) Fill the master cylinder reservoir with brake
fluid.
(2) If calipers are overhauled, open all caliper
bleed screws. Then close each bleed screw as fluid
starts to drip from it. Top off master cylinder reser-
voir once more before proceeding.
(3) Attach one end of bleed hose to bleed screw
and insert opposite end in glass container partially
filled with brake fluid (Fig. 1). Be sure end of bleed
hose is immersed in fluid.
(4) Open up bleeder, then have a helper press
down the brake pedal. Once the pedal is down close
the bleeder. Repeat bleeding until fluid stream is
clear and free of bubbles. Then move to the next
wheel.
STANDARD PROCEDURE - PRESSURE
BLEEDING
Use Mopar brake fluid, or an equivalent quality
fluid meeting SAE J1703-F and DOT 3 standards
only. Use fresh, clean fluid from a sealed container at
all times.
Do not pump the brake pedal at any time while
bleeding. Air in the system will be compressed into
small bubbles that are distributed throughout the
hydraulic system. This will make additional bleeding
operations necessary.
Do not allow the master cylinder to run out of fluid
during bleed operations. An empty cylinder will allow
additional air to be drawn into the system. Check the
cylinder fluid level frequently and add fluid as
needed.
Bleed only one brake component at a time in the
following sequence:
Follow the manufacturers instructions carefully
when using pressure equipment. Do not exceed the
tank manufacturers pressure recommendations. Gen-
erally, a tank pressure of 51-67 kPa (15-20 psi) is suf-
ficient for bleeding.
Fill the bleeder tank with recommended fluid and
purge air from the tank lines before bleeding.
Do not pressure bleed without a proper master cyl-
inder adapter. The wrong adapter can lead to leak-
age, or drawing air back into the system. Use
adapter provided with the equipment or Adapter
6921.
Fig. 1 Bleed Hose Setup
1 - BLEED HOSE
2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID
WJBRAKES - BASE 5 - 5
BRAKES - BASE (Continued)

(8) Secure caliper to nearby suspension part with
wire.Do not allow brake hose to support caliper
weight.
(9) Remove the inboard brake shoe from the cali-
per (Fig. 12).
(10) Remove the outboard brake shoe (Fig. 13)
from the caliper anchor.REMOVAL - REAR DISC BRAKE SHOES
(1) Raise and support vehicle.
(2) Remove rear wheel and tire assembly.
(3) Drain small amount of fluid from master cylin-
der brake reservoir with acleansuction gun.
(4) Bottom caliper pistons into the caliper by pry-
ing the caliper over (Fig. 14).
Fig. 11 Caliper Slide
1 - SLIDE PIN
2 - SLIDE PIN
3 - CALIPER
Fig. 12 Inboard Brake Shoe
1 - CALIPER
2 - INBOARD SHOE
Fig. 13 Outboard Brake Shoe
1 - CALIPER ANCHOR
2 - OUTBOARD BRAKE SHOE
Fig. 14 Bottoming Caliper Piston
1 - CALIPER
2 - CALIPER ANCHOR
5 - 12 BRAKES - BASEWJ
BRAKE PADS / SHOES (Continued)

(5) Remove the caliper support spring by prying
the spring out of the caliper (Fig. 15).
(6) Remove the caliper slide pin bushing caps and
remove the slide pins (Fig. 16).(7) Remove caliper from the anchor.
(8) Secure caliper to nearby suspension part with
wire.Do not allow brake hose to support caliper
weight.
(9) Remove the inboard brake shoe from the cali-
per (Fig. 17).
(10) Remove outboard brake shoe (Fig. 18) from
the caliper anchor.
INSTALLATION
INSTALLATION - FRONT DISC BRAKE SHOES
(1) Install the inboard brake shoe onto the caliper
(Fig. 12).
(2) Install the outboard shoe onto the caliper
anchor (Fig. 13).
(3) Lubricate the slide pins and slide pin bushings
with Dow Corningtgrease G807 or the grease pro-
vided with the brake shoes.
(4) Install caliper on the caliper anchor.
(5) Install the caliper slide pin and tighten to
29-41 N´m (21-30 ft. lbs.).
(6) Install the caliper slide pin bushing caps.
(7) Install the caliper support spring in the top
end of the caliper and under the anchor. Then install
other end into the lower caliper hole. Hold the spring
into the caliper hole with your thumb while prying
the end of the spring out and down under the anchor
with a screw drive.
Fig. 15 Caliper Support Spring
1 - CALIPER
2 - ANCHOR
3 - SUPPORT SPRING
Fig. 16 Caliper Slide Pins
1 - CALIPER
2 - SLIDE PINS
Fig. 17 Inboard Brake Shoe
1 - CALIPER
2 - INBOARD SHOE
WJBRAKES - BASE 5 - 13
BRAKE PADS / SHOES (Continued)

DISASSEMBLY
DISASSEMBLY - FRONT DISC BRAKE CALIPER
(1) Drain the brake fluid from caliper.
(2) C-clamp a block of wood over one piston (Fig.
27).
(3) Take another piece of wood and pad it with
one-inch thickness of shop towels. Place this piece in
the outboard shoe side of the caliper in front of the
other piston. This will cushion and protect caliper
piston during removal (Fig. 28).(4) To remove the caliper piston directshort
bursts of low pressure airwith a blow gun
through the caliper brake hose port. Use only enough
air pressure to ease the piston out.
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston.
WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS COULD
RESULT IN PERSONAL INJURY.
(5) Remove the C-clamp and block of wood from
the caliper and clamp it over the dust boot of the
first piston removed. This will seal the empty piston
bore.
(6) Move the padded piece of wood in front of the
other piston.
(7) Remove the second piston using the same pro-
cedure withshort bursts of low pressure air.
(8) Remove piston dust boots with a suitable pry
tool (Fig. 29)and discard.
Fig. 27 C-Clamp One Piston
1 - BLOCK OF WOOD
2 - C-CLAMP
3 - CALIPER
Fig. 28 Protect Caliper Piston
1 - CALIPER
2 - PADDED BLOCK OF WOOD
3 - C-CLAMP
Fig. 29 Piston Dust Boot Removal
1 - CALIPER
2 - PISTON DUST BOOT
WJBRAKES - BASE 5 - 17
DISC BRAKE CALIPERS (Continued)

(9) Remove piston seals from caliper (Fig. 30) and
discard.
CAUTION: Do not scratch piston bore while remov-
ing the seals.
(10) Remove caliper slide pin bushings (Fig. 31).
(11) Remove caliper bleed screw.
DISASSEMBLY - REAR DISC BRAKE CALIPER
(1) Drain brake fluid out of caliper.
(2) Take a piece of wood and pad it with one-inch
thickness of shop towels. Place this piece in the out-
board shoe side of the caliper in front of the piston.This will cushion and protect caliper piston during
removal (Fig. 32).
(3) To remove caliper piston directshort bursts
of low pressure airwith a blow gun through the
caliper brake hose port (Fig. 33). Use only enough air
pressure to ease the piston out.
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston.
WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS MAY RESULT
IN PERSONAL INJURY.
Fig. 30 Piston Seal
1 - CALIPER
2 - PISTON BORE
3 - PISTON SEAL
Fig. 31 Caliper Slide Pin Bushings
1 - CALIPER
2 - BUSHING
3 - CALIPER SLIDE PIN
Fig. 32 Padding Caliper Interior
1 - SHOP TOWELS OR CLOTHS
2 - CALIPER
Fig. 33 Caliper Piston Removal
1 - CALIPER PISTON
2 - AIR GUN
3 - PADDING MATERIAL
5 - 18 BRAKES - BASEWJ
DISC BRAKE CALIPERS (Continued)

STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING PROCEDURE
A new master cylinder should be bled before instal-
lation on the vehicle. Required bleeding tools include
bleed tubes and a wood dowel to stroke the pistons.
Bleed tubes can be fabricated from brake line.
(1) Mount master cylinder in vise with brass jaws.
(2) Attach bleed tubes to cylinder outlet ports.
Then position each tube end into the bottom of the
reservoir (Fig. 50).
(3) Fill reservoir with fresh brake fluid.
(4) Press cylinder pistons inward with wood dowel.
Then release pistons and allow them to return under
spring pressure. Continue bleeding operations until
air bubbles are no longer visible in fluid.
REMOVAL
(1) Remove the wire connector from the brake fluid
level sensor.
(2) Remove brake lines from master cylinder.
(3) Remove nuts that attach master cylinder to
booster studs (Fig. 51).
(4) Remove master cylinder from booster.
INSTALLATION
NOTE: Bleed new master cylinder on bench before
installation, refer to Service Procedures.
(1) Have an assistant depress the brake pedal
while guiding the master cylinder on the booster rod
and mounting studs.
CAUTION: Do not depress brake pedal too hard and
ensure the booster rod is in the master cylinder pis-
ton or booster/master cylinder damage will occur.(2) Install master cylinder mounting nuts and
tighten nuts to 25 N´m (18 lb. lbs.).
NOTE: Use original or factory replacement nuts only.
(3) Install brake lines and tighten to 16 N´m (144
in. lbs.).
(4) Install fluid level sensor connector.
(5) Fill and bleed brake system.
PEDAL
DESCRIPTION
DESCRIPTION - STANDARD PEDAL
A suspended-type brake pedal is used, the pedal
pivots on a shaft mounted in the pedal support
bracket. The bracket is attached to the dash panel.
The brake pedal assembly and pedal pad are the
only serviceable component.
DESCRIPTION - ADJUSTABLE PEDALS
The Adjustable Pedals System (APS) is designed to
enable the fore and aft repositioning of the brake and
accelerator pedals. This results in improved ergonom-
ics in relation to the steering wheel for taller and
shorter drivers. Being able to adjust the pedal posi-
Fig. 50 Master Cylinder Bleeding
1 - BLEEDING TUBES
2 - RESERVOIR
Fig. 51 Master Cylinder Mounting
1 - MOUNTING NUT
2 - SENSOR CONNECTOR
3 - MOUNTING NUT
4 - BRAKE LINES
WJBRAKES - BASE 5 - 25
MASTER CYLINDER (Continued)

STANDARD PROCEDURE - DISC ROTOR
MACHINING
CAUTION: For vehicles equipped with the Quadra-
Drive System, consisting of the NV-247 transfer case
and a Vari-Lok differential in the front and rear axles,
the following steps must be done prior to the use of a
hub mounted on-vehicle brake lathe. Disconnect the
driveshaft (Refer to 3 - DIFFERENTIAL & DRIVELINE/
PROPELLER SHAFT/PROPELLER SHAFT - REMOVAL)
from the respective axle on which the brake rotors are
being machined. Temporarily remove both brake cali-
pers (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - REMOVAL) from the axle
while disc rotor machining is in process. Both steps
will prevent unnecessary loads to the hub mounted
on-vehicle lathe and speed machining times. Install a
thread lock material to the driveshaft attaching bolts
when reinstalling (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
INSTALLATION).
NOTE: A hub mounted on-vehicle lathe is recom-
mended. This type of lathe trues the rotor to the vehi-
cles hub/bearing.
The disc brake rotor can be machined if scored or
worn. The lathe must machine both sides of the rotor
simultaneously with dual cutter heads. The rotor
mounting surface must be clean before placing on the
lathe. Equipment capable of machining only one side at
a time may produce a tapered rotor.
CAUTION: Brake rotors that do not meet minimum
thickness specifications before or after machining
must be replaced.
REMOVAL
REMOVAL - FRONT DISC BRAKE ROTOR
NOTE: Front rotors and hub/bearings are matched
mounted for minimum lateral runout. Before removing
the rotor, mark the rotor and hub/bearing to maintain
original orientation.
(1) Raise and support the vehicle.
(2) Remove wheel and tire assembly.
(3) Remove the caliper anchor bolts (Fig. 64) and
remove the caliper and anchor as an assembly from the
steering knuckle.
(4) Secure caliper anchor assembly to nearby suspen-
sion part with a wire.Do not allow brake hose to
support caliper weight.
(5) Mark the rotor and hub/bearing to maintain orig-
inal orientation. Remove retainers securing rotor to hub
studs.
(6) Remove rotor from hub/bearing.
REMOVAL - REAR DISC BRAKE ROTOR
(1) Raise and support the vehicle.
(2) Remove wheel and tire assembly.
(3) Remove the caliper anchor bolts (Fig. 65).
(4) Remove caliper and anchor as an assembly.(5) Secure caliper anchor assembly to nearby suspen-
sion part with wire.Do not allow brake hose to sup-
port caliper weight.
(6) Remove retainers securing rotor to axle studs.
(7) Remove rotor off axle studs.
Fig. 64 Caliper Anchor Bolts
1 - KNUCKLE
2 - ANCHOR
3 - ANCHOR BOLTS
4 - ROTOR
Fig. 65 Caliper Anchor Bolts
1 - ROTOR
2 - ANCHOR
3 - ANCHOR BOLTS
WJBRAKES - BASE 5 - 33
ROTORS (Continued)
2002 WJ Service Manual
Publication No. 81-370-02064
02WJ5-33 June, 2002

(7) Raise and support the vehicle.
(8) Remove the wheel and tire assemblies.
(9) Remove the brake calipers, caliper anchors and
rotors.
(10) Remove the ABS sensor wiring harness (Fig.
74)from the rear brake cables.
(11) Remove the cable retainer bolts (Fig. 74) from
the rear spring pads.
(12) Pull the cables out of the upper suspension
arm brackets.
(13) Push the cable in and lift up the end of cable
with a small screw driver to disengage the cable from
the parking brake actuator (Fig. 75).
(14) Remove the cable from the vehicle.
INSTALLATION
INSTALLATION - FRONT PARKING BRAKE
CABLE
(1) Install thecable into the parking brake lever
bracket and equalizer bracket.
(2) Install the front cable to the floor pan and
install retainer nuts.
(3) Engage the front cable ends to the parking
brake lever and equalizer.
(4) Install the front carpet, (Refer to 23 - BODY/
INTERIOR/CARPETS AND FLOOR MATS -
INSTALLATION).
(5) Pull on the lever to release the lock out spring.
(6) Install the center console, (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - INSTALLATION).
(7) Fold down the rear carpet cover and rear seat.
INSTALLATION - REAR PARKING BRAKE
CABLES
(1) Install the cables through the caliper anchor
mount. Then push the end of cable strand in to
engage the cable end to the parking brake actuator.
(2) Feed the other end of the cables through the
body and into the equalizer bracket (Fig. 76).
Fig. 74 Left Rear Parking Brake Cable
1 - CABLE BRACKET
2 - UPPER SUSPENSION ARM
3 - PARKING BRAKE CABLE
4 - CABLE RETAINER
5 - ABS SENSOR WIRING
Fig. 75 Parking Brake
1 - CABLE END
2 - SCREW DRIVER
3 - PARKING BRAKE ACTUATOR
4 - BRAKE SHOES
Fig. 76 Equalizer Bracket
1 - EQUALIZER
2 - RIGHT REAR CABLE
3 - LEFT REAR CABLE
4 - FRONT CABLE
WJBRAKES - BASE 5 - 37
CABLES (Continued)

(3) Push the cables into the upper suspension arm
brackets.
(4) Install the cable retainer bolts to the rear
spring pads.
(5) Install the ABS sensor wiring harness to the
rear brake cables.
(6) Install the rotors, caliper anchors and brake
calipers.
(7) Install the wheel and tire assemblies.
(8) Remove support and lower the vehicle.
(9) Engage the cable ends into the parking brake
equalizer.
(10) Pull on the lever to release the lock out
spring.
(11) Install center console, (Refer to 23 - BODY/IN-
TERIOR/FLOOR CONSOLE - INSTALLATION).
(12) Fold down the rear carpet cover and rear seat.
(13) Verify parking brake operation.
LEVER
REMOVAL
(1) Remove center console,(Refer to 23 - BODY/IN-
TERIOR/FLOOR CONSOLE - REMOVAL).
(2) Lift up rear seat and carpet covering the park-
ing brake cables.
(3) Place a screw driver through the front cable
eyelet (Fig. 77) and pry back on the front cable.(4) Have an assistant pry down the lock out spring
through the hole in the side of the park brake lever
(Fig. 78) with a small screw driver. Then slowly
release the front cable.
NOTE: Their should be slack in the cable if the lock
out spring is engaged.
(5) Disconnect parking brake switch wiring con-
nector.
(6) Disengage front cable end from parking brake
lever.
(7) Compress the cable retainer with a 13 mm
wrench (Fig. 79) and remove the cable from the park-
ing brake lever bracket.
Fig. 77 FRONT CABLE
1 - REAR CABLES
2 - FRONT CABLE EYELET
3 - FRONT CABLE
4 - EQUALIZER
Fig. 78 Lock Out Spring
1 - LOCK OUT SPRING
Fig. 79 Parking Brake Lever Bracket
1 - FRONT CABLE
2 - WRENCH
5 - 38 BRAKES - BASEWJ
CABLES (Continued)

G-SWITCH
DESCRIPTION
The G-switch (Fig. 4) is located under the rear
seat. The switch has directional arrow and must be
mounted with the arrow pointing towards the front
of the vehicle.
OPERATION
The switch is monitored by the CAB at all times.
The switch contains three mercury switches which
monitor vehicle deceleration rates (G-force). Sudden
changes in deceleration rates trigger the switch,
sending a signal to the CAB.
REMOVAL
(1) Fold the rear seat bottom assembly up for
access to the switch.
(2) Lift up the carpeting and disconnect the switch
harness (Fig. 5).
(3) Remove the switch mounting bolts and remove
the switch.
INSTALLATION
CAUTION: The mercury switch (inside the
G-Switch), will not function properly if the switch is
installed incorrectly. Verify that the switch locating
arrow is pointing to the front of the vehicle (Fig. 6).
(1) Note the position of the locating arrow on the
switch. Position the switch so the arrow faces for-
ward.
(2) Install the switch and tighten the mounting
bolts to 5.6 N´m (50 in. lbs.).
Fig. 2 Left Sensor Connector
1 - LEFT FRONT WHEEL SPEED SENSOR CONNECTOR
2 - ENGINE EXHAUST PIPE
3 - LEFT FRONT FRAME RAIL
4 - FRONT DRIVESHAFT
Fig. 3 Right Sensor Connector
1 - RIGHT FRONT WHEEL SPEED SENSOR CONNECTOR
2 - ENGINE EXHAUST Y-PIPE
3 - RIGHT FRONT FRAME RAIL
4 - RIGHT LOWER SUSPENSION ARM
Fig. 4 G-Switch
1 - SWITCH PART NUMBER
2 - ARROW INDICATES FRONT OF SWITCH FOR PROPER
MOUNTING
5 - 44 BRAKES - ABSWJ
FRONT WHEEL SPEED SENSOR (Continued)