light JEEP CHEROKEE 1995 Service Workshop Manual

(8) Remove outboard shoe. Press one end of shoe
inward to disengage shoe lug. Then rotate shoe up-
ward until retainer spring clears caliper. Press oppo-
site end of shoe inward to disengage shoe lug and
rotate shoe up and out of caliper (Fig. 7).
(9) Remove inboard shoe. Grasp ends of shoe and
tilt shoe outward to release springs from caliper pis-
ton (Fig. 8). Then remove shoe from caliper.
(10) Secure caliper to nearby suspension part with
wire.Do not allow brake hose to support caliper
weight.
(11) Wipe caliper off with shop rags or towels.Do
not use compressed air. Compressed air can un-
seat dust boot and force dirt into piston bore.
(12) Inspect condition of caliper piston dust boot
(Fig. 9). Overhaul caliper if there is evidence of leak-
age past piston and dust boot. Then inspect caliper
bushings and boots (Fig. 9). Replace boots if torn or
cut. If bushings or boots are damaged, replace them.
DISC BRAKESHOE INSTALLATION
(1) Clean brakeshoe mounting ledge slide surfaces
of steering knuckle with wire brush. Then apply light
coat of Mopar multi-mileage grease to slide surfaces
(Fig. 10).
(2) Lubricate caliper mounting bolts and bushings
(Fig. 10). Use GE 661 or Dow 111 silicone grease.
(3) Keep new or original brakeshoes in sets. Do not
interchange them.
(4) Install inboard shoe in caliper (Fig. 11). Be sure
shoe retaining springs are fully seated in caliper pis-
ton.
(5) Install outboard shoe in caliper (Fig. 12). Start
one end of shoe in caliper. Rotate shoe downward and
into place until shoe locating lugs and shoe spring
are seated.
(6) Verify that locating lugs on outboard shoe are
seated in caliper (Fig. 6).
(7) Install caliper. Position notches at lower end of
brakeshoes on bottom mounting ledge (Fig. 13). Then
Fig. 7 Removing Outboard Brakeshoe
Fig. 8 Removing Inboard Brakeshoe
Fig. 9 Caliper Dust Boots And Bushing Locations
Fig. 10 Caliper Lubrication Points
JDISC BRAKES 5 - 47

DISC BRAKE ROTOR REFINISHING
When To Refinish
Rotor braking surfaces can be refinished by sand-
ing and/or machining in a disc brake lathe. However,
the rotor should be cleaned and inspected before-
hand. Careful inspection will avoid refinishing rotors
with very little service life left in them.
Pay particular attention to rotors that are heavily
rusted, or corroded. Accumulated rust/corrosion on
braking surfaces and ventilating ribs may extend to
a depth beyond acceptable limits. This can be espe-
cially true on: (a) high mileage vehicles; (b) vehicles
regularly exposed to road salt during winter months;
(c) vehicles operated in coastal regions where salt air/
road splash is a factor; (d) and vehicles used for ex-
tensive off-road operation.
New rotors have a protective coating that should be
removed before installation.It is not necessary to
machine a rotor 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.
Recommended Refinishing Equipment
The brake lathe must be capable of machining both
rotor surfaces simultaneously with dual cutter heads
(Fig. 30).Equipment capable of machining only
one side at a time will produce a tapered rotor.
The lathe should also be equipped with a grinder at-
tachment, or dual sanding discs for final cleanup or
light refinishing.
Refinishing Techniques
If the rotor surfaces only need minor cleanup of
rust, scale, or scoring, use abrasive sanding discs to
clean up the rotor surfaces. However, when a rotor is
scored or worn, machining with cutting tools will be
required.
Light cuts are recommended when machining the
rotor surfaces. Heavy feed rates are not recom-
mended and may result in chatter marks, or taper.
CAUTION: Never refinish a rotor if machining would
cause the rotor to fall below minimum allowable
thickness.
The final finish on the rotor should be a non-direc-
tional, cross hatch pattern (Fig. 31). Use sanding
discs to produce this finish.
Fig. 30 Rotor Refinishing Equipment
JDISC BRAKES 5 - 53

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

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

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

(8) Remove shift handle by pulling upward sharply
on handle. Then remove shift bezel (Fig. 7).
(9) Remove console cover screws (Figs. 9 and 10).
(10) On models with power mirror switch, pry
switch out of console cover and disconnect switch
connector (Fig. 9).
(11) Remove cover from console (Fig. 10).
(12) Remove screws attaching console to brackets
and shifter covers (Fig. 11).
(13) Remove console (Fig. 11).
(14) Remove duct (Fig. 11).
(15) Disconnect wire at parking brake switch on le-
ver (Fig. 4).
(16) Remove lever and cable tensioner assembly
from floorpan.
(17) Move cover and boot aside for access to lever
arm (Fig. 4).
(18) Remove E-clip and pin that connect tensioner
to lever arm (Fig. 4).
(19) Parking brake switch can be replaced at this
time if necessary.
PARKING BRAKE LEVER INSTALLATION (XJ WITH
FULL CONSOLE)
(1) Assemble lever and tensioner (Figs. 4 and 5).
Be sure E-clip is fully engaged in retaining pin (Fig.
4).
(2) Verify that tensioner boot is fully seated in
cover (Fig. 6).
(3) Position assembled lever and tensioner in floor-
pan.(4) Install parking brake switch on lever if re-
moved, and connect brake warning light wires to
switch.
(5) Install duct and console (Fig. 11).
(6) Connect power mirror switch wire to switch
and install switch in console cover.
(7) Install console cover.
(8) On automatic transmission models, install shift
bezel and shift handle.
(9) On manual transmission models, install bezel,
outer boot, and shift knob.
(10) Raise vehicle.
(11) Insert tensioner rod in equalizer and install
adjusting nut on tensioner rod.
(12) Install nuts attaching lever support plate to
floorpan and lever.
(13) Adjust parking brakes. Refer to procedure in
this section.
(14) Lower vehicle and verify proper parking brake
operation.PARKING BRAKE LEVER REMOVAL (XJ WITHOUT
CONSOLE)
(1) Raise vehicle.
(2) Remove nuts attaching lever support plate to
underside of floorpan.
Fig. 9 Console Cover Screws And Power Mirror
Switch Connector
Fig. 10 Console Cover And Base
5 - 64 PARKING BRAKESJ

(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. 12).
(6) Remove cover attaching screws. Or, if cover is
attached with rivets, drill out and remove cover.
(7) Disconnect parking brake warning light wire at
switch on lever. Remove switch if replacement is nec-
essary.
(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. 4 and 5).
(2) Verify that tensioner boot is properly seated in
cover (Fig. 6).
(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) Install parking brake switch on lever, if re-
moved, and connect warning light wires to switch.
(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.
Fig. 11 Full Console Components (XJ)
JPARKING BRAKES 5 - 65