light JEEP CHEROKEE 1994 Service Workshop Manual

(9) Fill reservoir and bleed brakes. Refer to proce-
dure in this section.
(10) Install air cleaner and hoses.
PEDAL TRAVEL SENSOR SERVICE
CAUTION: The pedal travel sensor and booster
must form a matched set. The cap on the sensor
plunger and booster shell are color coded for iden-
tification, and to ensure they are used as matched
sets. Be sure the color of the sensor cap and the
color dot on the booster shell are the same before
installation. Refer to the Sensor Replacement infor-
mation before installing a new or original sensor.
PEDAL TRAVEL SENSOR REMOVAL
(1) Disconnect wires at sensor.
(2) Pump brake pedal to exhaust all vacuum from
booster.
(3) Unseat sensor retaining ring.
(4) Remove sensor from booster (Fig. 8).
PEDAL TRAVEL SENSOR REPLACEMENT
A new pedal travel sensor is supplied with four dif-
ferent color caps. The caps are color coded to ease
matching them with the color code dot on the booster
shell.
Compare the color of the new sensor cap and the
color dot on the booster shell. If the colors match,
proceed with sensor installation. However, if the col-
orsdo not match, select and install the correct color
cap on the sensor plunger before proceeding.
PEDAL TRAVEL SENSOR INSTALLATION
(1) Check color dot on face of brake booster. Then
check color of cap on sensor plunger. If colors match,
proceed with installation. If colors do not match, in-
stall correct color cap on end of plunger.
(2) Install O-ring on sensor.
(3) Install sensor retaining ring on booster flange.
(4) Insert sensor in retaining ring and booster.
(5) Verify that retaining ring is properly engaged
in sensor and that sensor is seated in booster.
(6) Connect wires to sensor.
(7) Check sensor operation with DRB II scan tool.
POWER BRAKE BOOSTER REMOVAL
(1) Pump brake pedal until all vacuum is ex-
hausted from power brake booster.
(2) Disconnect pedal travel sensor.
(3) Remove air cleaner and hoses.
(4) Remove clamps that secure reservoir hoses to
HCU pipes. Then remove hoses from pipes.
(5) Disconnect brakelines at master cylinder.
(6) Remove combination valve bracket bolt if nec-
essary.
(7) Remove nuts attaching master cylinder to
booster mounting studs.(8) Remove master cylinder. Pull cylinder forward
and off studs. Then work cylinder past combination
valve, brakelines, pedal travel sensor and out of en-
gine compartment.
(9) Disconnect vacuum hose at booster check valve.
(10) Disconnect booster push rod from brake pedal.
(11) Remove nuts attaching booster to passenger
compartment side of dash panel.
(12) Slide booster forward and work it out of en-
gine compartment.
POWER BRAKE BOOSTER INSTALLATION
(1) Position booster on dash panel. Align booster
mounting studs with holes in panel and seat booster
(Fig. 9).
(2) In passenger compartment, install booster at-
taching nuts on mounting studs. Tighten attaching
nuts to 41 Nzm (30 ft. lbs.) torque.
(3) Install seal on master cylinder. Seal is slight
interference fit to help hold it in place.
Fig. 8 Pedal Travel Sensor Mounting
Fig. 9 Booster Attachment At Dash PanelÐYJ
Shown
JABS COMPONENT SERVICE 5 - 51

PARKING BRAKE LEVER REMOVAL (XJ WITH FULL
CONSOLE)
(1) Release parking brakes, if necessary.
(2) Raise vehicle.
(3) Remove adjusting nut from tensioner rod. Then
temporarily secure equalizer to nearby chassis com-
ponent with wire.
(4) Remove nuts attaching lever support plate to
underside of floorpan.
(5) Lower vehicle.
(6) On models with manual transmission, remove
shift knob, boot and bezel.
(7) On models with automatic transmission, re-
move shift handle cap and remove plunger, spring
and T-lock (Fig. 7).
(8) Remove shift handle and shift bezel (Fig. 7).
(9) Remove console cover screws (Fig. 8).(10) On models with power mirror switch, pry
switch out of console cover and disconnect switch
connector (Fig. 8).
(11) Remove console cover from base (Fig. 9).
(12) Remove console base.
(13) Disconnect brake warning light wire connec-
tor at lever.
(14) Remove lever and cable tensioner assembly
from floorpan.
(15) Move cover and boot aside for access to lever
arm (Fig. 3).
(16) Remove E-clip and pin that connect tensioner
to lever arm (Fig. 3).
Fig. 6 Hand Lever And Cable Tensioner Components (XJ)
Fig. 5 Tensioner Boot Seated In Cover
Fig. 7 Automatic Transmission Shift Handle
JPARKING BRAKES 5 - 59

PARKING BRAKE LEVER INSTALLATION (XJ WITH
FULL CONSOLE)
(1) Assemble lever and tensioner (Figs. 3 and 4).
Be sure E-clip is fully engaged in retaining pin (Fig.
3).
(2) Verify that tensioner boot is fully seated in
cover (Fig. 5).
(3) Position assembled lever and tensioner in floor-
pan.
(4) Connect brake warning light wires to switch on
lever.
(5) Install console base and cover.
(6) Connect power mirror switch wire to switch
and install switch in console cover.
(7) On automatic transmission models, install shift
bezel and shift handle.
(8) On manual transmission models, install boot,
bezel and shift knob.
(9) Raise vehicle.
(10) Insert tensioner rod in equalizer and install
adjusting nut on tensioner rod.
(11) Install nuts attaching lever support plate to
floorpan and lever.
(12) Adjust parking brakes. Refer to procedure in
this section.
PARKING BRAKE LEVER REMOVAL (XJ WITHOUT
CONSOLE)
(1) Raise vehicle.
(2) Remove nuts attaching lever support plate to
underside of floorpan.
(3) Remove adjusting nut from tensioner rod. Then
temporarily secure equalizer and cables to nearby
chassis component with wire.
(4) Lower vehicle.
(5) Raise lever cover at rear and tilt it forward
(Fig. 10).
(6) Remove cover attaching screws. Or, if cover is
attached with rivets, drill out and remove cover.
(7) Disconnect brake warning light wire at lever.
(8) Remove lever and tensioner assembly from
floorpan.
(9) Move cover and boot aside for access to ten-
sioner retaining pin and clip.
(10) Remove pin and E-clip that secure tensioner
to lever arm and separate lever and tensioner.
PARKING BRAKE LEVER INSTALLATION (XJ
WITHOUT CONSOLE)
(1) Assemble lever and tensioner (Figs. 3 and 4).
(2) Verify that tensioner boot is properly seated in
cover (Fig. 5).
(3) Position lever on floorpan and insert lever
screws through floorpan. Be sure lever cover and seal
are in place between lever and floorpan.
(4) Connect brake warning light wires to switch on
lever.
Fig. 8 Console Cover Screws And Power Mirror
Switch Connector
Fig. 9 Console Cover And Base
5 - 60 PARKING BRAKESJ

(5) Install lever cover. Secure cover with new riv-
ets, or original attaching screws.
(6) Raise vehicle.
(7) Connect tensioner to lever with retaining pin
and E-clip.
(8) Install nuts attaching lever support plate to le-
ver screws.
(9) Adjust parking brakes. Refer to procedure in
this section.
PARKING BRAKE CABLE TENSIONER
REPLACEMENT (XJ)
(1) Raise vehicle.
(2) Remove adjuster nut from tensioner rod. Secure
equalizer and cables to nearby chassis component
with wire.
(3) Remove nuts attaching lever assembly to sup-
port plate and floorpan.
(4) Lower vehicle.
(5) Remove console components and lever assembly
cover.
(6) Remove lever and tensioner assembly.
(7) Move cover and boot for access to tensioner re-
taining pin.
(8) Remove E-clip and pin that attach tensioner to
lever arm (Fig. 3).
(9) Remove tensioner from cover.
(10) Transfer boot to new tensioner if necessary.
(11) Attach tensioner to lever arm with pin and
E-clip.
(12) Verify that E-clip is fully engaged in pin (Fig.
3).(13) Align cover and seal on lever flange.
(14) Verify that tensioner boot is seated in cover
(Fig. 5).
(15) Install assembled lever and tensioner in floor-
pan.
(16) Install necessary console components.
(17) Adjust parking brakes as described in this sec-
tion.
PARKING BRAKE PEDAL REMOVAL (YJ)
(1) Raise vehicle.
(2) Loosen equalizer nuts until front cable is slack
(Fig. 11).
(3) Lower vehicle.
(4) Remove dash-to-instrument panel brace rod, if
equipped.
(5) Disconnect warning light switch wire from
pedal assembly.
(6) On some YJ models, a ground wire may be at-
tached to upper end of bolt that secures parking
brake pedal to instrument panel. Wire is secured
with a nut. Be sure to remove nut and detach ground
wire before proceeding. If this wire is not removed
beforehand, wire and harness could be damaged
when pedal assembly bolt is removed. Ground wire
and attaching nut are accessible from under instru-
ment panel.
(7) Remove bolt securing pedal assembly to instru-
ment panel (Fig. 12).
(8) In engine compartment, remove pedal mount-
ing stud nuts.
(9) Remove pedal assembly from panel.
(10) Disengage front cable from retainer (Fig. 12).
(11) Squeeze cable clip (Fig. 12) and pull cable out
of pedal frame.
(12) Remove pedal assembly.
PARKING BRAKE PEDAL INSTALLATION (YJ)
(1) Connect front cable to pedal retainer.
Fig. 10 Lever Cover (XJ)
Fig. 11 Front Cable And Equalizer (YJ)
JPARKING BRAKES 5 - 61

(2) Position pedal assembly on panel and install
mounting stud nuts and pedal-to-dash bolt.
(3) Install ground wire on upper end of pedal-to-
dash bolt and secure wire with attaching nut.
(4) Connect warning light switch wire to pedal
connector.
(5) Install dash-to-instrument panel brace rod, if
equipped.
(6) Raise vehicle and adjust brake cables. Refer to
procedure in Service Adjustment section.
PARKING BRAKE REAR CABLE REPLACEMENT (XJ)
(1) Raise vehicle and loosen equalizer nuts until
rear cables are slack.
(2) Disengage cable from equalizer and remove ca-
ble clip and spring (Fig. 13).
(3) Remove rear wheel and brake drum.
(4) Remove secondary brakeshoe and disconnect
cable from lever on brakeshoe.
(5) Compress cable retainer with worm drive hose
clamp (Fig. 14) and remove cable from backing plate.
(6) Install new cable in backing plate. Be sure ca-
ble retainer is seated.
(7) Attach cable to lever on brakeshoe and install
brakeshoe on backing plate.
(8) Adjust brakeshoes to drum with brake gauge.
(9) Install brake drum and wheel.
(10) Engage cable in equalizer and install equal-
izer nuts (Fig. 13).
(11) Adjust parking brakes. Refer to procedure in
this section.
PARKING BRAKE FRONT CABLE REPLACEMENT
(YJ)
(1) Raise vehicle.
(2) Remove equalizer nuts (Fig. 15).
(3) Remove front cable from equalizer (Fig. 15).
(4) Remove cable-to-frame bracket clip.
(5) Lower vehicle.(6) Move front carpeting away from pedal.
(7) Compress clip securing cable to pedal frame
(Fig. 15). Use hose clamp to compress clip.
(8) Disconnect cable from pedal retainer and re-
move cable.
(9) Remove grommet (Fig. 15) from old cable and
transfer it to new cable, if necessary.
(10) Install new cable in floorpan and connect it to
pedal assembly.
(11) Seat cable grommet in floorpan.
Fig. 12 Parking Brake Pedal Assembly (YJ)
Fig. 13 Parking Brake Cables (XJ)
Fig. 14 Compressing Rear Cable Retainer
5 - 62 PARKING BRAKESJ

BRAKE PEDAL AND BRAKELIGHT SWITCH
INDEX
page page
Brake Pedal Installation.................... 66
Brake Pedal Removal..................... 65
Brake Pedal Service...................... 65
Brakelight Switch Adjustment................ 66Brakelight Switch Installation................ 66
Brakelight Switch Removal................. 66
General Information....................... 65
GENERAL INFORMATION
A suspended-type brake pedal is used on all models
(Figs. 1 and 2). The pedal pivots on a shaft mounted
in the pedal support bracket. The bracket is attached
to the dash and instrument panels on all models.
A plunger-type, adjustable brakelight switch is
used on all models. The switch is attached to a flange
on the pedal support bracket.
BRAKE PEDAL SERVICE
The brake pedal is a serviceable component. The
pedal, pivot pin, sleeve, pedal bushings and spacers/
washers are all replaceable parts. The pedal bracket
can also be replaced when necessary.
BRAKE PEDAL REMOVAL
(1) Remove lower trim panel and A/C duct if neces-
sary.
(2) Remove steering column lower trim panel and be-
zel.
(3) Remove necessary dash panel-to-instrument
panel brace rods.
Fig. 1 Brake Pedal And Support Bracket (YJ)
Fig. 2 Brake Pedal And Support Bracket (XJ)
JBRAKE PEDAL AND BRAKELIGHT SWITCH 5 - 65

(4) Remove retainer clip securing booster push rod
to pedal (Fig. 3).
(5) Remove nut securing pedal shaft in support
bracket.
(6) Slide pedal shaft outward for clearance and re-
move brake pedal.
(7) Remove pedal bushings if they are to be re-
placed.
BRAKE PEDAL INSTALLATION
(1) Install new bushings in pedal. Lubricate bush-
ings and pivot pin with Mopar multi mileage grease.
(2) Position pedal, sleeve and spacer(s) in bracket
and install pivot pin.
(3) Install new nut on pivot pin.Pivot pin nut is
specially formed and should not be reused. Be
sure to install new nut to secure pin.
(4) ) Tighten new pivot pin nut to 27 Nzm (20 ft.
lbs.) on models with manual transmission. Tighten
nut to 35 Nzm (26 ft. lbs.) on models with automatic
transmission.
(5) Install booster push rod on pedal pin (Fig. 3).
Secure push rod with original, or new retainer clip if
necessary.
(6) Install dash brace rod, if equipped.
(7) Check and adjust brakelight switch if neces-
sary. Refer to procedure in this section.
BRAKELIGHT SWITCH REMOVAL
The brakelight switch is mounted in the pedal sup-
port bracket and is operated by the pedal. The switch
is secured in the bracket with a retainer (Fig. 4).
(1) Remove steering column cover and lower trim
panel for switch access, if necessary.
(2) Disconnect switch wires.
(3) Thread switch out of retainer, or rock switch
up/down and pull it rearward out of retainer.
(4) Inspect switch retainer. Replace retainer if
worn, distorted, loose, or damaged.
BRAKELIGHT SWITCH INSTALLATION
(1) Insert replacement switch in retainer. Thread
switch into place or rock it up/down until switch
plunger touches brake pedal.
(2) Connect switch wires.
(3) Check switch operation. Adjust switch position
if necessary. Refer to procedures in this section.
(4) Install trim panels (if removed).
BRAKELIGHT SWITCH ADJUSTMENT
A plunger-type brakelight switch is used on XJ
and YJ models (Fig. 4). The switch plunger is actu-
ated directly by the brake pedal.
The switch internal contacts are open when the
brake pedal is in the released position. Brake appli-
cation moves the pedal away from the switch allow-
ing the plunger to extend. As the plunger extends,
the switch internal contacts close completing the cir-
cuit to the brakelights.
A circular, metal clip is used to secure the switch
to the bracket on the pedal support. The clip has
tangs that seat in the threads of the switch plunger
barrel.
SWITCH ADJUSTMENT PROCEDURE
(1) Check switch adjustment. Move the brake
pedal forward by hand and note operation of the
switch plunger. Plunger should be fully extended
when pedal free play is taken up and brake applica-
tion begins. A clearance of approximately 3 mm (1/8
in.) should exist between plunger and pedal at this
point.
(a) If switch-to-pedal clearance is OK and brake-
lights operate correctly, adjustment is not required.
(b) If switch plunger does not fully extend and
clearance between pedal and switch barrel is insuf-
ficient, adjust switch position as described in step
(2).
Fig. 3 Push Rod Attachment At Brake Pedal (XJ)
Fig. 4 Brakelight Switch Mounting And Location
(XJ/YJ)
5 - 66 BRAKE PEDAL AND BRAKELIGHT SWITCHJ

(2) Grasp brake pedal and pull it rearward as far
as possible. Switch plunger barrel will ``ratchet'' rear-
ward in retaining clip to correct position.
(3) Verify brakelight switch operation and proper
clearance between switch plunger and brake pedal.CAUTION: Be very sure the brake pedal returns to a
fully released position after adjustment. The switch
can interfere with full pedal return if too far forward.
The result will be brake drag caused by partial
brake application.
SPECIFICATIONS
BRAKE TORQUE SPECIFICATIONS
JSPECIFICATIONS 5 - 67

CLUTCH SERVICE
INDEX
page page
Clutch Cover and Disc Installation............ 10
Clutch Cover and Disc Removal............. 10
Clutch Fluid Level........................ 14
Clutch Housing Replacement................ 11
Clutch Hydraulic Linkage Installation.......... 12
Clutch Hydraulic Linkage Removal........... 11Clutch Pedal Installation................... 15
Clutch Pedal Removal..................... 15
Clutch Safety Precautions.................. 10
Flywheel Service......................... 15
Pilot Bearing Replacement................. 11
Release Bearing Replacement............... 11
CLUTCH SAFETY PRECAUTIONS
WARNING: EXERCISE CARE WHEN SERVICING
CLUTCH COMPONENTS. DUST AND DIRT ON
CLUTCH PARTS USE MAY CONTAIN ASBESTOS FI-
BERS. BREATHING EXCESSIVE CONCENTRATIONS
OF THESE FIBERS CAN CAUSE SERIOUS BODILY
HARM. WEAR A RESPIRATOR DURING SERVICE
AND NEVER CLEAN CLUTCH COMPONENTS WITH
COMPRESSED AIR OR WITH A DRY BRUSH. EI-
THER CLEAN THE COMPONENTS WITH A WATER
DAMPENED RAGS OR USE A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR REMOVING ASBES-
TOS FIBERS AND DUST. DO NOT CREATE DUST
BY SANDING A CLUTCH DISC. REPLACE THE DISC
IF THE FRICTION MATERIAL IS DAMAGED OR
CONTAMINATED. DISPOSE OF ALL DUST AND
DIRT CONTAINING ASBESTOS FIBERS IN SEALED
BAGS OR CONTAINERS. THIS WILL HELP MINIMIZE
EXPOSURE TO YOURSELF AND TO OTHERS. FOL-
LOW ALL RECOMMENDED SAFETY PRACTICES
PRESCRIBED BY THE OCCUPATIONAL SAFETY
AND HEALTH ADMINISTRATION (OSHA) AND THE
ENVIRONMENTAL SAFETY AGENCY (EPA), FOR
THE HANDLING AND DISPOSAL OF PRODUCTS
CONTAINING ASBESTOS.
CLUTCH COVER AND DISC REMOVAL
(1) Remove transmission. Refer to procedures in
Group 21.
(2) If original clutch cover will be reinstalled,
mark position of cover on flywheel for assembly ref-
erence. Use paint or a scriber for this purpose.
(3) If clutch cover is to be replaced, cover bolts can
be removed in any sequence. However, if original
cover will be reinstalled, loosen cover bolts evenly
and in rotation to relieve spring tension equally.
This is necessary avoid warping cover.
(4) Remove cover bolts and remove cover and disc
(Fig. 2).
CLUTCH COVER AND DISC INSTALLATION
(1) Lightly scuff sand flywheel face with 180 grit
emery cloth. Then clean surface with a wax and
grease remover.
(2) Lubricate pilot bearing with Mopar high tem-
perature bearing grease.
(3) Check runout and free operation of new clutch
disc as follows:
(a) Slide disc onto transmission input shaft
splines. Disc should slide freely on splines.
(b) Leave disc on shaft and check face runout
with dial indicator. Check runout at disc hub and
about 6 mm (1/4 in.) from outer edge of facing.
(c) Face runout should not exceed 0.5 mm (0.020
in.). Obtain another clutch disc if runout exceeds
this limit.
(4) Position clutch disc on flywheel. Be sure side of
disc marked flywheel side is positioned against fly-
wheel (Fig. 2). If disc is not marked, be sure flat side
of disc hub is toward flywheel.
(5) Insert clutch alignment tool in clutch disc (Fig.
3).
(6) Insert alignment tool in pilot bearing and posi-
tion disc on flywheel. Be sure disc hub is positioned
correctly. Side of hub marked Flywheel Side should
face flywheel (Fig. 2). If disc is not marked, place flat
side of disc against flywheel.
(7) Position clutch cover over disc and on flywheel
(Fig. 3).
(8) Install clutch cover bolts finger tight.
(9) Tighten cover bolts evenly and in rotation a
few threads at a time.Cover bolts must be tight-
ened evenly and to specified torque to avoid dis-
torting cover. Tightening torques are 31 Nzm (23
ft. lbs.) on 2.5L engines and 54 Nzm (40 ft. lbs.) on
4.0L engines.
(10) Apply light coat of Mopar high temperature
bearing grease to pilot bearing hub and splines of
transmission input shaft.Do not overlubricate
shaft splines. This will result in grease contami-
nation of disc.
(11) Install transmission (Fig. 4). Refer to proce-
dures in Group 21.
6 - 10 CLUTCH SERVICEJ

RELEASE BEARING REPLACEMENT
(1) Remove transmission as described in Group 21.
(2) Disconnect release bearing from release lever
and remove bearing (Fig. 5).
(3) Inspect bearing slide surface of transmission
front bearing retainer. Replace retainer if slide sur-
face is scored, worn, or cracked.
(4) Inspect release fork and fork pivot. Be sure
pivot is secure and in good condition. Be sure fork is
not distorted or worn. Replace release fork retainer
spring if bent or damaged in any way.
(5) Lubricate crankshaft pilot bearing with Mopar
high temperature bearing grease. Apply grease to
end of long shank, small diameter flat blade screw-
driver. Then insert tool through clutch disc hub to
reach bearing.
(6) Lubricate input shaft splines, bearing retainer
slide surface, fork pivot and release fork pivot sur-face with Mopar high temperature grease.
(7) Install new release bearing. Be sure bearing is
properly secured to release fork.
(8) Install transmission as described in Group 21.
PILOT BEARING REPLACEMENT
(1) Remove transmission. Refer to Group 21 for
procedure.
(2) Remove clutch cover and disc.
(3) Remove pilot bearing. Use internal (blind hole)
puller such those as supplied in Snap On Tool Set
CG40CB to remove bearing.
(4) Lubricate new bearing with Mopar high tem-
perature bearing grease.
(5) Start new bearing into crankshaft by hand.
Then seat bearing with clutch alignment tool (Fig.
6).
(6) Lightly scuff sand flywheel surface with 180
grit emery cloth. Then clean surface with wax and
grease remover.
(7) Install clutch disc and cover as described in
this section.
(8) Install transmission. Refer to Group 21 for pro-
cedure.
CLUTCH HOUSING REPLACEMENT
The AX 15 clutch housing is removable and can be
replaced when the transmission is out of the vehicle.
The bolts attaching the housing to the transmis-
sion case are located inside the housing (Fig. 7). Rec-
ommended tightening torque for the clutch housing-
to-transmission bolts is 38 Nzm (28 ft. lbs.).
Be sure the transmission and housing mating
surfaces are clean before installing an original,
or replacement clutch housing. Dirt/foreign ma-
terial trapped between the housing and trans-
mission will cause misalignment. If
misalignment is severe enough, the result will be
clutch drag, incomplete release and hard shift-
ing.
CLUTCH HYDRAULIC LINKAGE REMOVAL
The clutch master cylinder, slave cylinder and
connecting line are serviced as an assembly
only. The linkage components cannot be over-
hauled or serviced separately. The cylinders and
connecting line are sealed units. Also note that
removal/installation procedures for right and
left hand drive models are basically the same.
Only master cylinder location is different.
(1) Raise vehicle.
(2) Remove fasteners attaching slave cylinder to
clutch housing.
(3) Remove slave cylinder from clutch housing
(Fig. 8).
(4) Disengage clutch fluid line from body clips.
(5) Lower vehicle.
Fig. 2 Clutch Disc Position
Fig. 3 Typical Method Of Aligning Clutch Disc
JCLUTCH SERVICE 6 - 11