JEEP CHEROKEE 1995 Service Repair Manual

WHEEL NUT TIGHTENING
The wheel attaching nuts must be tightened prop-
erly to ensure efficient brake operation. Overtighten-
ing the nuts or tightening them in the wrong
sequence can cause distortion of the brake rotors and
drums. Impact wrenches are not really recommended
for tightening wheel nuts. A torque wrench should be
used for this purpose.
A light coat of LPS Anti-Corrosion spray lube
around the hub face and on the studs will cut down
on rust/corrosion formation.The correct tightening sequence is important in
avoiding rotor and drum distortion. The correct se-
quence is in a diagonal crossing pattern (Fig. 32).
Recommended torque range for XJ/YJ wheel nuts
is 108-149 Nzm (80-110 ft. lbs.). Preferred set-to
torque is 129 Nzm (95 ft. lbs.) torque.
Seat the wheel and install the wheel nuts finger
tight. Tighten the nuts in the sequence to 1/2 the re-
quired torque. Then repeat the tightening sequence
to final specified torque.
Fig. 31 Preferred Rotor Surface Finish
Fig. 32 Wheel Nut Tightening Sequence
5 - 54 DISC BRAKESJ

DRUM BRAKES
INDEX
page page
Brake Drum Refinishing.................... 58
Drum Brake Adjustment.................... 57
Drum Brakeshoe Installation................. 55
Drum Brakeshoe Removal................... 55
Support Plate Replacement.................. 58Wheel Cylinder Installation.................. 58
Wheel Cylinder Overhaul.................... 57
Wheel Cylinder Removal.................... 57
Wheel Nut Tightening...................... 59
DRUM BRAKESHOE REMOVAL (Figs. 1 and 2)
(1) Raise vehicle and remove rear wheels.
(2) Remove and discard spring nuts securing
drums to wheel studs.
(3) Remove brake drums. If drums prove difficult
to remove, retract brakeshoes. Remove access plug at
the rear of backing plate and back off adjuster screw
with brake tool and screwdriver.
(4) Remove U-clip and washer securing adjuster
cable to parking brake lever.
(5) Remove primary and secondary return springs
from anchor pin with Brake Spring Plier Tool 8078.
(6) Remove holddown springs, retainers and pins
with standard retaining spring tool.
(7) Install spring clamps on wheel cylinders to hold
pistons in place.
(8) Remove adjuster lever, adjuster screw and
spring.
(9) Remove adjuster cable and cable guide.
(10) Remove brakeshoes and parking brake strut.(11) Disconnect cable from parking brake lever and
remove lever.
DRUM BRAKESHOE INSTALLATION
(1) Clean support plate with Mopar brake cleaner.
Replace support plate if worn, or rusted through at
any point. Do not attempt to salvage, or reuse a dam-
aged support plate.
(2) If new drums are being installed, remove pro-
tective coating with Mopar Carb cleaner followed by
final rinse with Mopar brake cleaner. A scotch brite
pad, or steel wool can also be used to help loosen and
remove coating if desired.It is not necessary to
machine drums to remove the coating.
(3) Clean and lubricate anchor pin with light coat
of Mopar multi-mileage grease.
(4) Apply Mopar multi-mileage grease to brakeshoe
contact surfaces of support plate (Figs. 3 and 4).
(5) Lubricate adjuster screw threads and pivot
with Mopar spray lube.
Fig. 1 Nine Inch Drum Brake Components
JDRUM BRAKES 5 - 55

(6) Attach parking brake lever to secondary brake-
shoe. Use new washer and U-clip to secure lever.
(7) Remove wheel cylinder clamps.
(8) Attach parking brake cable to lever.
(9) Install brakeshoes on support plate. Secure
shoes with new holddown springs, pins and retainers.
(10) Install parking brake strut and spring.
(11) Install guide plate and adjuster cable on an-
chor pin.
(12) Install primary and secondary return springs.
(13) Install adjuster cable guide on secondary shoe.
(14) Lubricate and assemble adjuster screw (Fig.
5).
(15) Install adjuster screw, spring and lever and
connect to adjuster cable.(16) Adjust shoes to drum as described in following
procedure.
(17) Install wheel/tire assemblies and lower vehi-
cle.
(18) Verify firm brake pedal before moving vehicle.
Fig. 2 Ten Inch Drum Brake Components
Fig. 3 Shoe Contact Surfaces (9-Inch Support Plate)
Fig. 4 Shoe Contact Surfaces (10-Inch Support
Plate)
5 - 56 DRUM BRAKESJ

DRUM BRAKE ADJUSTMENT
Rear drum brakes are equipped with a self adjust-
ing mechanism. Under normal circumstances, the
only time adjustment is required is when the shoes
are replaced, removed for access to other parts, or
when one or both drums are replaced.
The only tool needed for adjustment is a standard
brake gauge.
Adjustment is performed with the brakeshoes in-
stalled on the support plate. Procedure is as follows:
ADJUSTMENT PROCEDURE
(1) Raise and support vehicle rear end and remove
wheels and brake drums.
(2) Verify that left/right automatic adjuster lever
and cable are properly connected.
(3) Insert brake gauge in drum. Expand gauge un-
til gauge inner legs contact drum braking surface.
Then lock gauge in position (Fig. 6).
(4) Reverse gauge and install it on brakeshoes
(Fig. 6). Position gauge legs at shoe centers as
shown. If gauge does not fit (too loose or tight), ad-
just shoes.
(5) Pull shoe adjuster star wheel away from ad-
juster lever.(6) Turn adjuster star wheel (by hand) to expand
or retract brakeshoes. Continue adjustment until
gauge outside legs are light drag-fit on shoes (Fig. 7).
(7) Repeat adjustment at opposite brakeshoe as-
sembly.
(8) Install brake drums and wheels and lower ve-
hicle.
(9) Make final adjustment as follows:
(a) Drive vehicle and make one forward stop fol-
lowed by one reverse stop.
(b) Repeat procedure 8-10 times to actuate self
adjuster components and equalize adjustment.
(c)Bring vehicle to complete standstill at
each stop. Incomplete, rolling stops will NOT
activate adjuster mechanism.
WHEEL CYLINDER REMOVAL
(1) Raise vehicle and remove wheel.
(2) Disconnect brakeline at wheel cylinder.If cyl-
inder brakeline fitting is hard to break loose,
spray generous amount of Mopar Rust Pene-
trant between fitting and line and around fit-
ting threads in wheel cylinder. Note that it may
require a few minutes for penetrant to work.
(3) Remove brakeshoes.
(4) Remove bolts attaching wheel cylinder to sup-
port plate and remove cylinder.
WHEEL CYLINDER OVERHAUL (Figs. 8 and 9)
(1) Remove links.
(2) Remove dust boots.
(3) Remove cups and pistons. Discard cups.
(4) Remove and discard spring and expander.
(5) Remove bleed screw.
(6) Clean cylinder, pistons and links with Mopar
brake cleaner.
(7) Inspect cylinder bore and pistons. Light discol-
oration of bore is acceptable. However, replace cylin-
der if bore and pistons are scored, pitted, or corroded.
Fig. 5 Adjuster Screw Components (9-Inch Brake)
Fig. 6 Adjusting Gauge To Brake Drum
Fig. 7 Adjusting Brakeshoes To Gauge
JDRUM BRAKES 5 - 57

Do not hone cylinder bores or polish pistons.
Replace cylinder as an assembly if bore is dam-
aged.
(8) Install bleed screw.
(9) Coat cylinder bore, pistons, cups and expander
with brake fluid and reassemble cylinder compo-
nents. Be sure piston cup lips face expander.
WHEEL CYLINDER INSTALLATION
(1) Apply small bead of silicone sealer around cyl-
inder mounting surface of support plate.
(2) Start brakeline in wheel cylinder fitting by
hand.
(3) Align and seat wheel cylinder on support plate
(Fig. 10).
(4) Install cylinder mounting bolts (Fig. 10).
Tighten bolts to 10 Nzm (90 in. lbs.) torque.(5) Tighten brakeline fitting to 15 Nzm (132 in.
lbs.) torque.
(6) Install brakeshoes. Adjust shoes to drum with
brake gauge.
(7) Install brake drums and lower vehicle.
(8) Fill master cylinder and bleed brakes.
SUPPORT PLATE REPLACEMENT
The support plate should cleaned and inspected
whenever the drum brake components are being ser-
viced.
Check the support plate for wear, or rust through
at the contact pads and replace the plate if necessary.
Be sure to lubricate the contact pads with Mopar
multi-mileage grease before shoe installation. Lubri-
cation will avoid noisy operation and shoe bind.
(1) Raise vehicle and remove wheel/tire assembly.
(2) Remove brake drum, brakeshoes, and wheel
cylinder.
(3) Remove axle shaft as described in Group 3.
(4) Remove support plate attaching nuts and re-
move support plate.
(5) Clean axle tube flange. If gasket is not used on
flange, apply thin bead of silicone adhesive/sealer to
flange.
(6) Position new support plate on axle tube flange.
(7) Apply Mopar Lock N9Seal, or Loctite 242 to
support plate attaching nuts. Then install and
tighten nuts.
(8) Apply light coat of Mopar multi-mileage grease
to contact pads of new support plate.
(9) Install wheel cylinder and brakeshoes.
(10) Adjust brakeshoes to drums. Refer to proce-
dure in this section.
(11) Bleed brakes.
(12) Install wheel and tire assembly.
(13) Adjust parking brake cable tensioner. Refer to
procedure in Parking Brake section.
(14) Lower vehicle and verify proper service brake
and parking brake operation.
BRAKE DRUM REFINISHING
Brake drums can be machined to restore the brak-
ing surface. Use a brake lathe to clean up light scor-
ing and wear.
CAUTION: Never refinish a brake drum if machining
will cause the drum to exceed maximum allowable
brake surface diameter.
Brake drums that are warped, distorted, or se-
verely tapered should be replaced. Do not refinish
drums exhibiting these conditions. Brake drums that
are heat checked or have hard spots should also be
replaced.
Fig. 8 Wheel Cylinder (9-Inch Brake)
Fig. 9 Wheel Cylinder (10-Inch Brake)
Fig. 10 Wheel Cylinder Mounting
5 - 58 DRUM BRAKESJ

If the brake drums are heavily coated with rust,
clean and inspect them carefully. Rust damage on
high mileage drums can be severe enough to require
replacement.
New drums have a protective coating that should
be removed before installation.It is not necessary
to machine a drum to remove this coating. The
coating is easily removed with Mopar carb
cleaner followed by a rinse with Mopar brake
cleaner. A scotch brite pad, or steel wool can
also be used to help loosen and remove the
coating if desired.
The maximum allowable diameter for the drum
braking surface is usually indicated on the drum
outer face (Fig. 11).
WHEEL NUT TIGHTENING
The wheel attaching lug nuts must be tightened
properly to ensure efficient brake operation. Over-tightening the nuts or tightening them in the wrong
sequence can cause distortion of the brake rotors and
drums.
Impact wrenches are not recommended for tighten-
ing wheel nuts. A torque wrench should be used for
this purpose.
A light coat of LPS Anti-Corrosion spray lube
around the hub face and on the studs will cut down
on rust/corrosion formation.
The correct tightening sequence is important in
avoiding rotor and drum distortion. The correct se-
quence is in a diagonal crossing pattern (Fig. 12).
Recommended torque range for XJ/YJ wheel nuts
is 109-150 Nzm (80-110 ft. lbs.).
Seat the wheel and install the wheel nuts finger
tight. Tighten the nuts in the sequence to half the re-
quired torque. Then repeat the tightening sequence
to final specified torque.
Fig. 11 Typical Location Of Brake Drum Refinish
Limit
Fig. 12 Wheel Nut Tightening Sequence
JDRUM BRAKES 5 - 59

PARKING BRAKES
INDEX
page page
General Service Information................. 60
Parking Brake Cable Tensioner Adjustment (XJ/YJ).. 68
Parking Brake Cable Tensioner Replacement (XJ) . 65
Parking Brake Front Cable Replacement (YJ).... 67
Parking Brake Lever Installation (XJ with Full
Console).............................. 64
Parking Brake Lever Installation (XJ with Mini
Console).............................. 63
Parking Brake Lever Installation (XJ Without
Console).............................. 65Parking Brake Lever Removal (XJ with Full Console).63
Parking Brake Lever Removal (XJ with Mini
Console).............................. 62
Parking Brake Lever Removal (XJ Without Console).64
Parking Brake Operation.................... 60
Parking Brake Pedal Installation (YJ)........... 66
Parking Brake Pedal Removal (YJ)............ 66
Parking Brake Rear Cable Replacement (XJ)..... 66
Parking Brake Rear Cable Replacement (YJ)..... 68
Parking Brake Switch...................... 68
GENERAL SERVICE INFORMATION
Parking brake adjustment is controlled by a cable ten-
sioner mechanism.
The cable tensioner, once adjusted at the factory,
should not need further adjustment under normal
circumstances. There are only two instances when
adjustment is required. The first is when a new ten-
sioner, or cables have been installed. And the second,
is when the tensioner and cables are disconnected for
access to other brake components.
PARKING BRAKE OPERATION
The rear brakes are utilized for the parking brake
function. They are actuated hydraulically during nor-
mal brake operation but are mechanically actuated
for parking brake operation.
Parking Brake Components
The rear brakeshoes are applied by a system of le-
vers and cables for parking brake operation. A foot or
hand operated lever in the passenger compartment is
the main application device. Actuating levers on the
Fig. 1 Parking Brake Components (YJ)
5 - 60 PARKING BRAKESJ

secondary brakeshoes move the shoes directly into
contact with the drum braking surface. The actuating
levers are interconnected by a system of cables and a
tensioner mechanism. The tensioner mechanism con-
trols parking brake adjustment.
A parking brake switch is used on all models. It is
mounted on the parking brake lever or foot pedal and
is actuated by movement of the lever/pedal. The
switch, which is in circuit with the red warning light
in the dash, will illuminate the warning light when-
ever the parking brakes are applied.
On XJ models, the cable tensioner is part of the lever
assembly. On YJ models, the tensioner and equalizer
are mounted in a bracket attached to the underbody.
On YJ models, the parking brake front cable is at-
tached to the foot pedal and cable tensioner. The ten-
sioner and rear cables are connected to the equalizer
(Fig. 1).
On XJ models, the cable tensioner is connected di-
rectly to the hand lever (a front cable is not used).
The tensioner rod is attached to the equalizer which
is the connecting point for the rear cables (Fig. 2).
The rear cables are connected to the actuating le-
ver on each secondary brakeshoe. The levers are at-
tached to the brakeshoes by a pin either pressed into,
or welded to the lever. A clip is used to secure the pin
in the brakeshoe. The pin allows each lever to pivot
independently of the brakeshoe.
Struts installed between each brakeshoe, are used to
maintain shoe alignment and equal motion when the
parking brakes are applied. Each strut is equipped with
a combination tension and anti-rattle spring.
Parking Brake Application
To apply the parking brakes, the foot pedal is
pressed downward, or the hand lever is pulled up-
ward, to an engaged position. This pulls the rear
brakeshoe actuating levers forward, by means of the
interconnected tensioner and cables.
As the actuating lever is pulled forward, the park-
ing brake strut (which is connected to both shoes),
exerts a linear force against the primary brakeshoe.
This action presses the primary shoe into contact
with the drum.
Once the primary shoe contacts the drum, force ex-
erted through the strut does not stop. Instead, fur-
ther lever movement exerts continuing force against
the strut. This force is transferred through the strut
to the secondary brakeshoe causing it to pivot into
the drum as well.
The brakeshoes remain engaged with the drum until
the levers and cables are released. A gear type ratchet-
ing mechanism is used to hold the pedal or lever in an
applied position. Parking brake release is accomplished
by means of the release handle on YJ models. Or by the
hand lever release button on XJ models.
Fig. 2 Parking Brake Components (XJ)
JPARKING BRAKES 5 - 61

PARKING BRAKE LEVER REMOVAL (XJ WITH MINI
CONSOLE)
(1) Release parking brakes, if necessary.
(2) Raise vehicle.
(3) Remove adjusting nut from tensioner rod (Fig.
2). Then secure equalizer and rear cables to chassis
with wire.
(4) Remove nuts attaching lever support plate to
underside of floorpan. Then move plate aside.
(5) Lower vehicle.(6) Disconnect parking brake switch wire at switch
(Fig. 3).
(7) Remove parking brake lever assembly from
floorpan.
(8) Remove tensioner cover and boot for access to
lever arm (Fig. 4).
(9) Remove E-clip and pin that connect tensioner
to lever arm (Fig. 4).
(10) Remove lever attaching screws from floorpan
(Fig. 5).
(11) Remove lever assembly.
Fig. 3 Parking Brake Switch MountingFig. 4 Tensioner E-Clip And Retaining Pin Location
Fig. 5 Mini Console And Parking Brake Lever Cover (XJ)
5 - 62 PARKING BRAKESJ

(12) Parking brake switch can be serviced at this
time, if necessary.
PARKING BRAKE LEVER INSTALLATION (XJ WITH
MINI CONSOLE)
(1) Assemble lever and tensioner components (Figs.
4 and 5). Be sure E-clip is fully seated in pin (Fig. 4).
(2) Verify that tensioner boot is properly seated in
cover (Fig. 6).
(3) Position lever assembly on floorpan and install
lever attaching screws/nuts. Also install parking
brake switch if removed, or replaced.
(4) Raise vehicle.
(5) Insert cable tensioner rod in equalizer and in-
stall adjusting nut on tensioner rod (Fig. 7).
(6) Install and tighten nuts that attach lever sup-
port plate to floorpan and lever screws.
(7) Adjust parking brakes. Refer to procedure in
this section.
(8) Lower vehicle.
(9) Connect parking brake switch wire.
(10) Install lever trim cover, if equipped.(11) Verify correct parking brake operation.
PARKING BRAKE LEVER REMOVAL (XJ WITH FULL
CONSOLE)
(1) Release parking brakes.
(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, outer boot, and bezel.
(7) On models with automatic transmission, re-
move shift handle cap and remove plunger, spring
and T-lock (Fig. 8).
Fig. 7 Hand Lever And Cable Tensioner Components (XJ)
Fig. 6 Tensioner Boot Seated In Cover
Fig. 8 Automatic Transmission Shift Handle And Bezel
JPARKING BRAKES 5 - 63