JEEP YJ 1995 Service And Repair Manual

(14) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(15) Install new ring gear bolts and alternately
tighten to 95-122 Nzm (70-90 ft. lbs.) torque (Fig. 17).
(17) Lubricate all differential components with hy-
poid gear lubricant.
Fig. 17 Ring Gear Bolt Installation
3 - 50 REAR SUSPENSION AND AXLESJ

AXLE SPECIFICATIONS
MODEL 35 AXLE
Axle Type...............................Semi-Floating Hypoid
Lubricant................SAE Thermally Stable 80W-90
Lubricant Trailer Tow.............Synthetic 75W-140
Lube Capacity..............................1.66 L (3.50 pts.)
Axle Ratio................................3.07, 3.55, 3.73, 4.10
Differential
Bearing Preload ............................0.1 mm (0.004 in.)
Side Gear Clearance ............0-0.15 mm (0-0.006 in.)
Ring Gear
Diameter .......................................19.2 cm (7.562 in.)
Backlash.........................0-0.15 mm (0.005-0.008 in.)
Pinion Std. Depth...................96.8 mm (3.813 in.)
Pinion Bearing Preload
Original Bearing ....................1-2Nzm (10-20 in. lbs.)
New Bearing .......................1.5-4Nzm (15-35 in. lbs.)
8 1/4 AXLE
Axle Type................................Semi-floating, hypoid
Lubricant...............................................SAE 75W-90
Lube Capacity................................2.08 L (4.4 pts.)
Axle Ratios.........................................3.07 3.55 4.10
Differential
Side Gear Clearance ..................0.12 mm (0.005 in.)
Case Flange Runout ..................0.07 mm (0.003 in.)
Bearing Preload ...........................95 Nzm (70 ft. lbs.)
Ring Gear
Diameter .......................................20.95 cm (8.25 in.)
Backlash....................0.12-0.20 mm (0.005-0.008 in.)
Runout .......................................0.127 mm (0.005 in.)
Pinion Bearing
Preload ....................................1-2 Nzm (10-20 in.lbs.)
TORQUE SPECIFICATIONS
XJ REAR SUSPENSION COMPONENTS
DESCRIPTION ................................................TORQUE
Shock Absorber
Upper Bolt ...................................23 Nzm (17 ft. lbs.)
Lower Nut ....................................62 Nzm (46 ft. lbs.)
Stabilizer Bar
Clamp Bolt ...................................54 Nzm (40 ft. lbs.)
Link Upper Bolt ............................12 Nzm (9 ft. lbs.)
Link Lower Nut ..........................74 Nzm (55 ft. lbs.)
Spring
U-Bolt Nut ...................................70 Nzm (52 ft. lbs.)
Front Pivot Bolt ......................148 Nzm (109 ft. lbs.)
Upper Shackle Bolt .................148 Nzm (109 ft. lbs.)
Lower Shackle Bolt ...................108 Nzm (80 ft. lbs.)
YJ REAR SUSPENSION COMPONENTS
DESCRIPTION ................................................TORQUE
Shock Absorber
Upper Nut ....................................61 Nzm (45 ft. lbs.)
Lower Nut ....................................61 Nzm (45 ft. lbs.)
Track Bar
Frame Bracket Nut.................142 Nzm (105 ft. lbs.)
Axle Bracket Nut ....................142 Nzm (105 ft. lbs.)Spring
U-Bolt Nut .................................122 Nzm (90 ft. lbs.)
Rear Shackle Bolts..................136 Nzm (100 ft. lbs.)
Front Pivot Bolt ......................142 Nzm (105 ft. lbs.)
MODEL 35 AXLE
DESCRIPTION ................................................TORQUE
Fill Hole Plug...........................34 Nzm (25 ft. lbs.)
Diff. Cover Bolt........................41 Nzm (30 ft. lbs.)
Bearing Cap Bolt.....................77 Nzm (57 ft. lbs.)
Pinion Nut...............292-427 Nzm (215-315 ft. lbs.)
Ring Gear Bolt.............95-122 Nzm (70-90 ft. lbs.)
RWAL/ABS Sensor Bolt.........24 Nzm (18. ft. lbs.)
8 1/4 AXLE
DESCRIPTION ................................................TORQUE
Diff. Cover Bolt........................47 Nzm (35 ft. lbs.)
Bearing Cap Bolt.....................95 Nzm (70 ft. lbs.)
Pinion Nut.............................285 Nzm (210 ft. lbs.)
Ring Gear Bolt.........................95 Nzm (70 ft. lbs.)
RWAL/ABS Sensor Bolt.........24 Nzm (18. ft. lbs.)
JREAR SUSPENSION AND AXLES 3 - 51

BRAKES
CONTENTS
page page
ABS BRAKE DIAGNOSIS................... 3
ABS OPERATION AND SERVICE............ 33
BRAKE FLUIDÐBRAKE BLEEDINGÐ
BRAKELINES AND HOSES............... 10
DISC BRAKES.......................... 45
DRUM BRAKES......................... 55
GENERAL INFORMATION.................. 1MASTER CYLINDERÐCOMBINATION VALVE . . 15
PARKING BRAKES....................... 60
POWER BRAKE BOOSTERÐBRAKE PEDALÐ
BRAKELIGHT SWITCH.................. 22
SERVICE BRAKE DIAGNOSIS............... 4
SPECIFICATIONS........................ 70
GENERAL INFORMATION
INDEX
page page
Antilock Brakes (ABS)....................... 1
Brake Components......................... 1
Brake Fluid/Lubricants/Cleaning Solvents......... 2
Brake Safety Precautions.................... 2Brake Warning Lights....................... 1
Brakelining Material........................ 1
Jeep Body Code Letters..................... 2
BRAKE COMPONENTS
Power assist front disc and rear drum brakes are
standard on Cherokee/Wrangler models. Disc brake
components consist of single piston calipers and ven-
tilated rotors. Rear drum brakes are dual shoe units
with cast brake drums.
The parking brake mechanism is lever and cable
operated. The cables are attached to levers on the
rear drum brake secondary shoes. The parking
brakes are operated by a foot pedal on YJ models and
a hand lever on XJ models.
A 205 mm dual diaphragm vacuum power brake
booster is used for all applications. Two master cylin-
ders are used; 4-cylinder YJ models have a one-piece
master cylinder. All other models have a two-piece
master cylinder with plastic reservoir.
All models are equipped with a combination valve.
The valve contains a pressure differential valve and
switch and a fixed rate rear proportioning valve.
BRAKELINING MATERIAL
Factory brakelining on all models consists of an or-
ganic base material combined with metallic particles.
The lining does not contain asbestos.
BRAKE WARNING LIGHTS
Cherokee/Wrangler models are equipped with one
or two brake warning lights. A red warning light is
standard on all models. An amber light is added on
models with ABS brakes. Both lights are located in
the instrument panel.
The red light is in circuit with the pressure differ-
ential switch (in the combination valve), and with the
parking brake switch. The light alerts the driver
when the parking brakes are applied, or when a
pressure differential exists between the front and
rear hydraulic systems. The light also illuminates for
a few seconds at start up as part of a bulb check.
The ABS warning light is amber in color and is lo-
cated in the same side of the instrument cluster as
the red warning light. The amber light only illumi-
nates when an ABS circuit fault occurs.
ANTILOCK BRAKES (ABS)
An antilock brake system (ABS) is available on
Cherokee/Wrangler models as an option. The system
is an electronically operated, all-wheel brake control
system. The ABS system is designed to prevent
wheel lockup during periods of high wheel slip brak-
ing. Refer to the antilock brake section for operation
and service information.
JBRAKES 5 - 1

ABS SYSTEM CHANGES
A different master cylinder, power brake booster,
and HCU are used in the 1995 Jeep ABS system.
The master cylinder reservoir has a single filler cap
and is no longer interconnected with the HCU. The
new HCU has built-in accumulators. The pedal travel
sensor has been eliminated and a new dual dia-
phragm power brake booster is used.
BRAKE FLUID/LUBRICANTS/CLEANING SOLVENTS
Recommended fluid for all Jeep vehicles is Mopar
DOT 3 brake fluid, or an equivalent meeting SAE
J1703 and DOT 3 standards.
Use Mopar Multi Mileage grease to lubricate drum
brake pivot pins and rear brakeshoe contact points
on the support plates. Use GE 661, or Dow 111 sili-
cone grease on caliper bushings and mounting bolts.
Use fresh brake fluid or Mopar brake cleaner to
clean or flush brake system components. These are
the only cleaning materials recommended.
CAUTION: Never use gasoline, kerosene, methyl or
isopropyl alcohol, paint thinner, or any fluid con-
taining mineral oil to clean brake parts. These fluids
damage rubber cups and seals. If system contami-
nation is suspected, check the fluid for dirt, discol-
oration, or separation into distinct layers. Drain and
flush the system with new brake fluid if contamina-
tion is suspected.
JEEP BODY CODE LETTERS
The body/model identification code letters for Jeep
vehicles are as follows:²Code letters XJ: Cherokee
²Code letters YJ: Wrangler/YJ
The code letters are used throughout this group to
simplify model identification and component applica-
tion.
BRAKE SAFETY PRECAUTIONS
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKELINING ON JEEP VEHICLES IS MADE FROM
ASBESTOS FREE MATERIALS, SOME AFTER MAR-
KET BRAKELINING MAY CONTAIN ASBESTOS. THIS
SHOULD BE TAKEN INTO ACCOUNT WHEN RE-
PAIRING A VEHICLE WITH PRIOR BRAKE SERVICE.
WEAR A RESPIRATOR WHEN CLEANING BRAKE
COMPONENTS AS ASBESTOS FIBERS CAN BE A
HEALTH HAZARD. NEVER CLEAN WHEEL BRAKE
COMPONENTS WITH COMPRESSED AIR. USE A
VACUUM CLEANER SPECIFICALLY DESIGNED FOR
REMOVING BRAKE DUST. IF A VACUUM CLEANER
IS NOT AVAILABLE, CLEAN THE PARTS WITH WA-
TER DAMPENED SHOP RAGS. DO NOT CREATE
DUST BY SANDING BRAKELINING. DISPOSE OF
ALL DUST AND DIRT SUSPECTED OF CONTAINING
ASBESTOS FIBERS IN SEALED BAGS OR CON-
TAINERS. FOLLOW ALL SAFETY PRACTICES REC-
OMMENDED BY THE OCCUPATIONAL SAFETY AND
HEALTH ADMINISTRATION (OSHA) AND THE ENVI-
RONMENTAL PROTECTION AGENCY (EPA), FOR
HANDLING AND DISPOSAL OF ASBESTOS.
5 - 2 BRAKESJ

ABS BRAKE DIAGNOSIS
INDEX
page page
ABS Diagnostic Connector................... 3
ABS Warning Light Display................... 3
Antilock ECU and Hcu Diagnosis............... 3
DRB Scan Tool............................ 3General Information........................ 3
Normal Operating Conditions.................. 3
Wheel/Tire Size and Input Signals.............. 3
GENERAL INFORMATION
The DRB scan tool is required for ABS diagnosis.
The scan tool is used to identify ABS circuit faults.
Once a faulty circuit has been identified, refer to
the appropriate chassis/body diagnostic manual for
individual component testing.
ABS WARNING LIGHT DISPLAY
The amber antilock light illuminates at startup as
part of the system self check feature. The light illu-
minates for 2-3 seconds then goes off as part of the
normal check routine.
An ABS circuit fault is indicated when the amber
light remains on after startup, or illuminates during
vehicle operation.
Verify that a fault is actually related to the ABS
system before making repairs. For example, if the
red warning illuminates but the ABS light does not,
the problem is related to a service brake component
and not the ABS system. Or, if neither light illumi-
nates but a brake problem is noted, again, the prob-
lem is with a service brake component and not with
the ABS system.
ABS DIAGNOSTIC CONNECTOR
The ABS diagnostic connector is inside the vehicle.
The connector is the access point for the DRB scan tool.
On XJ models, the connector is located under the
instrument panel to the right of the steering column.
On some models, the connecter may be tucked under
the carpeting on the transmission tunnel. The con-
necter is a black, 6-way type.
On YJ models, the connector is under the instru-
ment panel by the the driver side kick panel. The
connecter is a black, 6 or 8-way type.
The DRB scan tool kit contains adapter cords for
both types of connecter. Use the appropriate cord for
test hookup.
DRB SCAN TOOL
ABS diagnosis is performed with the DRB scan tool.
Refer to the DRB scan tool manual for test hookup and
procedures. Diagnosis information is provided in the ap-
propriate chassis/body diagnostic manual.
WHEEL/TIRE SIZE AND INPUT SIGNALS
Antilock system operation is dependant on accurate
signals from the wheel speed sensors. Ideally, the ve-
hicle wheels and tires should all be the same size
and type. However, the Jeep ABS system is designed
to operate with a compact spare tire installed.
NORMAL OPERATING CONDITIONS
Sound Levels
The hydraulic control unit pump and solenoid valves
may produce some sound as they cycle on and off. This
is a normal condition and should not be mistaken for
faulty operation. Under most conditions, pump and so-
lenoid valve operating sounds will not be audible.
Vehicle Response In Antilock Mode
During antilock braking, the hydraulic control unit
solenoid valves cycle rapidly in response to antilock
electronic control unit signals.
The driver will experience a pulsing sensation
within the vehicle as the solenoids decrease, hold, or
increase pressure as needed. Brake pedal pulsing will
also be noted and is anormal condition.
Steering Response
A modest amount of steering input is required dur-
ing extremely high deceleration braking, or when
braking on differing traction surfaces. An example of
differing traction surfaces would be when the left
side wheels are on ice and the right side wheels are
on dry pavement.
Owner Induced Faults
Driving away with the parking brakes still applied
will cause warning light illumination. Pumping the
brake pedal will also generate a system fault and in-
terfere with ABS system operation.
ANTILOCK ECU AND HCU DIAGNOSIS
An ECU or HCU fault can only be determined
through testing with the DRB scan tool. Do not re-
place either component unless a fault is actually in-
dicated.
JABS BRAKE DIAGNOSIS 5 - 3

SERVICE BRAKE DIAGNOSIS
INDEX
page page
Brake Drag............................... 6
Brake Fade.............................. 6
Brake Fluid Contamination................... 7
Brake Noise.............................. 7
Brake Pull............................... 6
Brake Warning Light Operation................ 5
Brakes Do Not Hold After Driving Through Deep
Water Puddles........................... 7
Component Inspection...................... 5
Contaminated Brakelining.................... 7
Diagnosing Parking Brake Malfunctions.......... 8
Diagnosis Procedures....................... 4
General Information........................ 4Hard Pedal or High Pedal Effort............... 6
Low Pedal............................... 5
Master Cylinder/Power Booster Test............ 8
Pedal Falls Away.......................... 5
Pedal Pulsation (Non-ABS Brakes Only)......... 6
Power Booster Check Valve Test............... 9
Power Booster Vacuum Test.................. 9
Preliminary Brake Check..................... 4
Rear Brake Grab.......................... 7
Road Testing............................. 5
Spongy Pedal............................. 5
Wheel and Tire Problems.................... 7
GENERAL INFORMATION
The diagnosis information in this section covers
service brake components which include:
²disc brake calipers
²disc brakeshoes
²drum brake wheel cylinders
²drum brakeshoes and brake drums
²drum brake support plates
²parking brake mechanism
²master cylinder/combination valve
²vacuum power brake booster
²brake pedal and brakelight switch
²brake warning light
DIAGNOSIS PROCEDURES
Service brake diagnosis involves determining if a
problem is related to a mechanical, hydraulic or vac-
uum operated component. A preliminary brake check,
followed by road testing and component inspection
are needed to determine a problem cause.
Road testing will either verify proper brake opera-
tion or confirm the existence of a problem. Compo-
nent inspection will, in most cases, identify the
actual part responsible for a problem.
The first diagnosis step is the preliminary brake
check. This involves inspecting fluid level, parking
brake action, wheel and tire condition, checking for
obvious leaks or component damage and testing
brake pedal response. A road test will confirm or
deny the existence of a problem. The final diagnosis
procedure involves road test analysis and a visual in-
spection of brake components.
PRELIMINARY BRAKE CHECK
(1) If amber ABS light is illuminated, refer to ABS
Brake System Diagnosis. If red warning light is illu-
minated, or if neither warning light is illuminated,
continue with brake check.(2) Inspect condition of tires and wheels. Damaged
wheels and worn, damaged, or underinflated tires
can cause pull, shudder, tramp and a condition simi-
lar to grab.
(3) If complaint was based on noise when braking,
check suspension components. Jounce front and rear
of vehicle and listen for noise that might be caused
by loose, worn, or damaged suspension or steering
components.
(4) Inspect brake fluid level:
(a) If vehicle has one-piece master cylinder, fluid
level should be within 6 mm (1/4 in.) of reservoir
rim.
(b) If vehicle has nylon reservoir with single
filler cap, correct level is to FULL mark on side of
reservoir. Acceptable level is between FULL and
ADD marks.
(c) Remember that fluid level in the reservoir
compartments will decrease in proportion to nor-
mal lining wear. However, if fluid level is abnor-
mally low, look for leaks at calipers, wheel
cylinders, brakelines and master cylinder.
(5) Inspect brake fluid condition:
(a) Fluid should be free of foreign material.Note
that brake fluid tends to darken over time.
This is normal and should not be mistaken for
contamination. If fluid is clear of foreign ma-
terial, it is OK.
(b) If fluid is highly discolored, or appears to con-
tain foreign material, drain out a sample with a
clean suction gun. Pour sample in a glass container
and note condition described in step (c).
(c) If fluid separates into layers, obviously con-
tains oil, or a substance other than brake fluid,
system seals and cups will have to be replaced and
hydraulic system flushed.
(6) Check parking brake operation. Verify free
movement and full release of cables and foot pedal or
5 - 4 SERVICE BRAKE DIAGNOSISJ

hand lever. Also note if vehicle was being operated
with parking brake partially applied (this will cause
red light to remain on).
(7) Check brake pedal operation. Verify that pedal
does not bind and has adequate free play. If pedal
lacks free play, check pedal and power booster for be-
ing loose or for bind condition. Do not road test until
condition is corrected.
(8) If components inspected look OK, road test ve-
hicle.
ROAD TESTING
(1) If amber warning light is on, problem is with
antilock system component. Refer to antilock diagno-
sis section.
(2) If red warning light is not on, proceed to step
(4).
(3) If red warning light is on, proceed as follows:
(a) See if parking brakes are applied. If brakes
are applied, release them and proceed to step (4).
(b) Note if brake pedal is abnormally low. If
pedal is definitely low and red light is still on,
check front/rear hydraulic circuits for leak.Do not
road test. Inspect and repair as needed.
(4) Check brake pedal response with transmission
in Neutral and engine running. Pedal should remain
firm under steady foot pressure. If pedal falls away,
do not road test as problem is in master cylinder, or
HCU on ABS models. If pedal holds firm, proceed to
next step.
(5) During road test, make normal and firm brake
stops in 25-35 mph range. Note faulty brake opera-
tion such as hard pedal, pull, grab, drag, noise, fade,
etc.
(6) Return to shop and inspect brake components.
Refer to inspection and diagnosis information.
COMPONENT INSPECTION
Fluid leak points and dragging brake units can
usually be located without removing any components.
The area around a leak point will be wet with fluid.
The components at a dragging brake unit (wheel,
tire, rotor) will be quite warm or hot to the touch.
Other brake problem conditions will require compo-
nent removal for proper inspection. Raise the vehicle
and remove the necessary wheels for better visual ac-
cess.
During component inspection, pay particular atten-
tion to heavily rusted/corroded brake components
(e.g. rotors, caliper pistons, brake return/holddown
springs, support plates, etc.).
Heavy accumulations of rust may be covering se-
vere damage to a brake component. It is wise to re-
move surface rust in order to accurately determine
the depth of rust penetration and damage. Light sur-
face rust is fairly normal and not a major concern (as
long as it is removed). However, heavy rust buildup,especially on high mileage vehicles may cover struc-
tural damage to such important components as
brakelines, rotors, support plates, and brake boost-
ers. Refer to the wheel brake service procedures in
this group for more information.
BRAKE WARNING LIGHT OPERATION
The red brake warning light will illuminate under
the following conditions:
²for 2-3 seconds at startup as part of normal bulb
check
²when parking brakes are applied
²low pedal caused by leak in front/rear brake hy-
draulic circuit
If the red light remains on after startup, first ver-
ify that the parking brakes are fully released. Then
check pedal action and fluid level. A red light plus
low pedal indicates the pressure differential switch
and valve have been actuated due to a system leak.
On models with ABS brakes, the amber warning
light only illuminates when an ABS malfunction has
occurred. The ABS light operates independently of
the red warning light.
PEDAL FALLS AWAY
A brake pedal that falls away under steady foot
pressure is generally the result of a system leak. The
leak point could be at a brakeline, fitting, hose,
wheel cylinder, or caliper. Internal leakage in the
master cylinder caused by worn or damaged piston
cups, may also be the problem cause.
If leakage is severe, fluid will be evident at or
around the leaking component. However internal
leakage in the master cylinder will not be physically
evident. Refer to the cylinder test procedure at the
end of this section.
LOW PEDAL
If a low pedal is experienced, pump the pedal sev-
eral times. If the pedal comes back up, worn lining
and worn rotors or drums are the most likely causes.
However, if the pedal remains low and the red warn-
ing light is on, the likely cause is a leak in the hy-
draulic system.
A decrease in master cylinder fluid level may only
be the result of normal lining wear. Fluid level will
drop somewhat as lining wear occurs. It is a result of
the outward movement of caliper and wheel cylinder
pistons to compensate for normal wear.
SPONGY PEDAL
Air in the system is the usual cause of a spongy
pedal. Brake drums machined way beyond allowable
limits (too thin), or substandard brake lines and
hoses can also cause a condition similar to a spongy
JSERVICE BRAKE DIAGNOSIS 5 - 5

pedal. The proper course of action is to bleed the sys-
tem, or replace thin drums and suspect quality brake
lines and hoses.
HARD PEDAL OR HIGH PEDAL EFFORT
A hard pedal or high pedal effort may be due to lin-
ing that is water soaked, contaminated, glazed, or
badly worn. The power booster or check valve could
also be faulty. Test the booster and valve as described
in this section.
BRAKE DRAG
Brake drag occurs when the lining is in constant
contact with the rotor or drum. Drag can occur at one
wheel, all wheels, fronts only, or rears only. It is a
product of incomplete brakeshoe release. Drag can be
minor or severe enough to overheat the linings, ro-
tors and drums. A drag condition also worsens as
temperature of the brake parts increases.
Brake drag also has a direct effect on fuel economy.
If undetected, minor brake drag can be misdiagnosed
as an engine or transmission/torque converter prob-
lem.
Minor drag will usually cause slight surface char-
ring of the lining. It can also generate hard spots in
rotors and drums from the overheat/cool down pro-
cess. In most cases, the rotors, drums, wheels and
tires are quite warm to the touch after the vehicle is
stopped.
Severe drag can char the brake lining all the way
through. It can also distort and score rotors and
drums to the point of replacement. The wheels, tires
and brake components will be extremely hot. In se-
vere cases, the lining may generate smoke as it chars
from overheating.
An additional cause of drag involves the use of in-
correct length caliper mounting bolts. Bolts that are
too long can cause a partial apply condition. The cor-
rect caliper bolts have a shank length of 67 mm
(2.637 in.), plus or minus 0.6 mm (0.0236 in.). Refer
to the Disc Brake service section for more detail on
caliper bolt dimensions and identification.
Some common causes of brake drag are:
²loose or damaged wheel bearing
²seized or sticking caliper or wheel cylinder piston
²caliper binding on bolts or slide surfaces
²wrong length caliper mounting bolts (too long)
²loose caliper mounting bracket
²distorted rotor, brake drum, or shoes
²brakeshoes binding on worn/damaged support
plates
²severely rusted/corroded components
²misassembled components.
If brake drag occurs at all wheels, the problem may
be related to a blocked master cylinder compensatorport or faulty power booster (binds-does not release).
The condition will worsen as brake temperature in-
creases.
The brakelight switch can also be a cause of drag.
An improperly mounted or adjusted brakelight
switch can prevent full brake pedal return. The re-
sult will be the same as if the master cylinder com-
pensator ports are blocked. The brakes would be
partially applied causing drag.
BRAKE FADE
Brake fade is a product of overheating caused by
brake drag. However, overheating and subsequent
fade can also be caused by riding the brake pedal,
making repeated high deceleration stops in a short
time span, or constant braking on steep roads. Refer
to the Brake Drag information in this section for
causes.
PEDAL PULSATION (NON-ABS BRAKES ONLY)
Pedal pulsation is caused by parts that are loose,
or beyond tolerance limits. This type of pulsation is
constant and will occur every time the brakes are ap-
plied.
Disc brake rotors with excessive lateral runout or
thickness variation, or out of round brake drums are
the primary causes of pulsation.
On vehicles with ABS brakes, remember that pedal
pulsation is normal during antilock mode brake
stops. If pulsation occurs during light to moderate
brake stops, a standard brake part is either loose, or
worn beyond tolerance.
BRAKE PULL
A front pull condition could be the result of:
²contaminated lining in one caliper
²seized caliper piston
²binding caliper
²wrong caliper mounting bolts (too long)
²loose caliper
²loose or corroded mounting bolts
²improper brakeshoes
²damaged rotor
²incorrect wheel bearing adjustment (at one wheel)
A worn, damaged wheel bearing or suspension com-
ponent are further causes of pull. A damaged front
tire (bruised, ply separation) can also cause pull.
Wrong caliper bolts (too long) will cause a partial ap-
ply condition and pull if only one caliper is involved.
A common and frequently misdiagnosed pull condi-
tion is where direction of pull changes after a few
stops. The cause is a combination of brake drag fol-
lowed by fade at the dragging brake unit.
As the dragging brake overheats, efficiency is so re-
duced that fade occurs. If the opposite brake unit is
still functioning normally, its braking effect is magni-
5 - 6 SERVICE BRAKE DIAGNOSISJ

fied. This causes pull to switch direction in favor of
the brake unit that is functioning normally.
When diagnosing a change in pull condition, re-
member that pull will return to the original direction
if the dragging brake unit is allowed to cool down
(and is not seriously damaged).
REAR BRAKE GRAB
Rear grab (or pull) is usually caused by contami-
nated lining, bent or binding shoes and support
plates, or improperly assembled components. This is
particularly true when only one rear wheel is in-
volved. However, when both rear wheels are affected,
the master cylinder could be at fault.
BRAKES DO NOT HOLD AFTER DRIVING THROUGH
DEEP WATER PUDDLES
This condition is caused by water soaked lining. If
the lining is only wet, it can be dried by driving with
the brakes lightly applied for a mile or two. However,
if the lining is both wet and dirty, disassembly and
cleaning will be necessary.
CONTAMINATED BRAKELINING
Brakelining contaminated by water is salvageable.
The lining can either be air dried or dried using heat.
In cases where brakelining is contaminated by oil,
grease, or brake fluid, the lining should be replaced.
Replacement is especially necessary when fluids/lu-
bricants have actually soaked into the lining mate-
rial. However, grease or dirt that gets onto the lining
surface (from handling) during brake repairs, can be
cleaned off. Spray the lining surface clean with Mo-
par brake cleaner.
BRAKE FLUID CONTAMINATION
There are two basic causes of brake fluid contami-
nation. The first involves allowing dirt, debris, or
other materials to enter the cylinder reservoirs when
the cover is off. The second involves adding non-rec-
ommended fluids to the cylinder reservoirs.
Brake fluid contaminated with only dirt, or debris
usually retains a normal appearance. In some cases,
the foreign material will remain suspended in the
fluid and be visible. The fluid and foreign material
can be removed from the reservoir with a suction gun
but only if the brakes have not been applied. If the
brakes are applied after contamination, system flush-
ing will be required. The master cylinder may also
have to be disassembled, cleaned and the piston seals
replaced. Foreign material lodged in the reservoir
compensator/return ports can cause brake drag by re-
stricting fluid return after brake application.
Brake fluid contaminated by a non-recommended
fluid may appear discolored, milky, oily looking, or
foamy. However, remember that brake fluid will
darken in time and occasionally be cloudy in appear-ance. These are normal conditions and should not be
mistaken for contamination.
If some type of oil has been added to the system,
the fluid will separate into distinct layers. To verify
this, drain off a sample with a clean suction gun.
Then pour the sample into a glass container and ob-
serve fluid action. If the fluid separates into distinct
layers, it is definitely contaminated.
The only real correction for contamination by non-
recommended fluid is to flush the entire hydraulic
system and replace all the seals.
BRAKE NOISE
Squeak/Squeal
Factory installed brakelining is made from as-
bestos free materials. These materials have dif-
ferent operating characteristics than previous
lining material. Under certain conditions, as-
bestos free lining may generate some squeak,
groan or chirp noise. This noise is considered
normal and does not indicate a problem. The
only time inspection is necessary, is when noise
becomes constant or when grinding, scraping
noises occur.
Constant brake squeak or squeal may be due to lin-
ings that are wet or contaminated with brake fluid,
grease, or oil. Glazed linings, rotors/drums with hard
spots, and dirt/foreign material embedded in the
brake lining also cause squeak. Loud squeak, squeal,
scraping, or grinding sounds are a sign of severely
worn brake lining. If the lining has worn completely
through in spots, metal-to-metal contact occurs.
Thump/Clunk
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. However,
calipers that bind on the slide surfaces can generate
a thump or clunk noise. In addition, worn out, im-
properly adjusted, or improperly assembled rear
brakeshoes can also produce a thump noise.
Chatter/Shudder
Brake chatter, or shudder is usually caused by
loose or worn components, or glazed/burnt lining. Ro-
tors with hard spots can also contribute to chatter.
Additional causes of chatter are out of tolerance ro-
tors, brake lining not securely attached to the shoes,
loose wheel bearings and contaminated brake lining.
WHEEL AND TIRE PROBLEMS
Some conditions attributed to brake components
may actually be caused by a wheel or tire problem.
A damaged wheel can cause shudder, vibration and
pull. A worn or damaged tire can also cause pull.
Severely worn tires with very little tread left can
JSERVICE BRAKE DIAGNOSIS 5 - 7

produce a condition similar to grab as the tire loses
and recovers traction.
Flat-spotted tires can cause vibration and wheel
tramp and generate shudder during brake operation.
A tire with internal damage such as a severe bruise
or ply separation can cause vibration and pull. The
pull will be magnified when braking.
DIAGNOSING PARKING BRAKE MALFUNCTIONS
Adjustment Mechanism
Parking brake adjustment is controlled by a ca-
ble tensioner mechanism. The cable tensioner,
once adjusted at the factory, will not need further
attention under normal circumstances. There are
only two instances when adjustment is required.
The first is when a new tensioner, or cables have
been installed. And the second, is when the ten-
sioner and cables are disconnected for access to
other brake components.
Parking Brake Switch And Warning Light Illumination
The parking brake switch on the lever, or foot
pedal, is in circuit with the red warning light. The
switch will illuminate the red light only when the
parking brakes are applied. If the light remains on
after parking brake release, the switch or wires are
faulty, or cable tensioner adjustment is incorrect.
If the red light comes on while the vehicle is in mo-
tion and brake pedal height decreases, a fault has oc-
curred in the front or rear brake hydraulic system.
Parking Brake problem Causes
In most cases, the actual cause of an improperly
functioning parking brake (too loose/too tight/wont
hold), can be traced to a drum brake component.
The leading cause of improper parking brake
operation, is excessive clearance between the
brakeshoes and the drum surface. Excessive
clearance is a result of: lining and/or drum
wear; oversize drums; or inoperative shoe ad-
juster components.
Excessive parking brake lever travel (sometimes de-
scribed as a loose lever or too loose condition), is the re-
sult of worn brakeshoes/drums, improper brakeshoe
adjustment, or incorrectly assembled brake parts.
A ``too loose'' condition can also be caused by inop-
erative brakeshoe adjusters. If the adjusters are mis-
assembled, they will not function. In addition, since
the adjuster mechanism only works during reverse
stops, it is important that complete stops be made.
The adjuster mechanism does not operate when roll-
ing stops are made in reverse. The vehicle must be
brought to a complete halt before the adjuster lever
will turn the adjuster screw.
A condition where the parking brakes do not hold, will
most probably be due to a wheel brake component.
Items to look for when diagnosing a parking brake
problem, are:
²rear brakeshoe wear or adjuster problem
²rear brake drum wear
²brake drums machined beyond allowable diameter
(oversize)
²parking brake front cable not secured to lever
²parking brake rear cable seized
²parking brake strut reversed
²parking brake strut not seated in both shoes
²parking brake lever not seated in secondary shoe
²parking brake lever or brakeshoe bind on support
plate
²brakeshoes reversed
²adjuster screws seized
²adjuster screws reversed
²holddown or return springs misassembled or lack
tension
²wheel cylinder pistons seized
Brake drums that are machined oversize are diffi-
cult to identify without inspection. If oversize drums
are suspected, diameter of the braking surface will
have to be checked with an accurate drum gauge.
Oversize drums will cause low brake pedal and lack
of parking brake holding ability.
Improper parking brake strut and lever installation
will result in unsatisfactory parking brake operation.
Intermixing the adjuster screws will cause drag, bind
and pull along with poor parking brake operation.
Parking brake adjustment and parts replacement pro-
cedures are described in the Parking Brake section.
MASTER CYLINDER/POWER BOOSTER TEST
(1) Start engine and check booster vacuum hose
connections. Hissing noise indicates vacuum leak.
Correct any vacuum leak before proceeding.
(2) Stop engine and shift transmission into Neu-
tral.
(3) Pump brake pedal until all vacuum reserve in
booster is depleted.
(4) Press and hold brake pedal under light foot
pressure.
(a) If pedal holds firm, proceed to step (5).
(b) If pedal does not hold firm and falls away,
master cylinder is faulty due to internal leakage.
Overhaul or replace cylinder.
(5) Start engine and note pedal action.
(a) If pedal falls away slightly under light foot
pressure then holds firm, proceed to step (6).
(b) If no pedal action is discernible, or hard pedal
is noted, power booster or vacuum check valve is
faulty. Install known good check valve and repeat
steps (2) through (5).
(6) Rebuild booster vacuum reserve as follows: Re-
lease brake pedal. Increase engine speed to 1500
rpm, close throttle and immediately turn off ignition.
5 - 8 SERVICE BRAKE DIAGNOSISJ