air suspension JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
2SSuspension
3Differential & Driveline
5Brakes
5SBrakes
6Clutch
7Cooling
7SCooling
8AAudio
8BChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8LSLamps
8MMessage Systems
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
9SEngine
11Exhaust System
11SExhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transmission and Transfer Case
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Component and System Index
2.4L Gas Component and System Index
Service Manual Comment Forms
NOTE: For New Vehicle Preparation information, see the separate
publication, 81-170-00003.
NOTE: Group names with the suffix(S(indicate groups pertaining to the
the 2.4L Gas Supplement

SUSPENSION
TABLE OF CONTENTS
page page
SUSPENSION
DIAGNOSIS AND TESTING - SUSPENSION
AND STEERING SYSTEM................1WHEEL ALIGNMENT......................3
FRONT.................................7
REAR.................................16
SUSPENSION
DIAGNOSIS AND TESTING - SUSPENSION AND
STEERING SYSTEM
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn wheel bearings. 1. Replace wheel bearings.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
EXCESSIVE PLAY IN
STEERING1. Loose or worn wheel bearings. 1. Replace wheel bearings.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.
EXCESSIVE STEERING
EFFORT1. Loose or worn steering gear. 1. Adjust or replace steering gear.
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
4. Tire pressure. 4. Adjust tire pressure.
5. Alignment. 5. Align vehicle to specifications.
VEHICLE PULLS TO ONE
SIDE DURING BRAKING1. Uneven tire pressure. 1. Adjust tire pressure.
2. Worn brake components. 2. Repair brakes as necessary.
3. Air in brake line. 3. Repair as necessary.
KJSUSPENSION 2 - 1

CONDITION POSSIBLE CAUSES CORRECTION
VEHICLE LEADS OR
DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON
UNCROWNED ROAD1. Radial tire lead. 1. Cross front tires.
2. Brakes dragging. 2. Repair brake as necessary.
3. Weak or broken spring. 3. Replace spring.
4. Uneven tire pressure. 4. Adjust tire pressure.
5. Wheel Alignment. 5. Align vehicle.
6. Loose or worn steering or
suspension components.6. Repair as necessary.
7. Cross caster out of spec. 7. Align vehicle.
KNOCKING, RATTLING
OR SQUEAKING1. Worn shock bushings. 1. Replace shock.
2. Loose, worn or bent steering/
suspension components.2. Inspect, tighten or replace components
as necessary.
3. Shock valve. 3. Replace shock.
IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as
necessary.
2. Loose, worn or bent steering/
suspension components.2. Inspect, tighten or replace components
as necessary.
2 - 2 SUSPENSIONKJ
SUSPENSION (Continued)

(5) Align the marks front and rear at the cam/
pivot bolts and tighten the bolts. Tighten the bolts to
170 N´m (125 ft.lbs.)
(6) Install the stabilizer link bolt at the lower con-
trol arm. Tighten the bolt to 136 N´m (100 ft.lbs.)
(7) Install the lower clevis bracket bolt at the
lower control arm. Tighten the bolt to 150 N´m (110
ft.lbs.)
(8) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(9) Perform a full wheel alignment (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
SHOCK
REMOVAL
REMOVAL - LEFT SIDE
(1) Disconnect the battery.
(2) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(3) Unclip the power center and move it to the side
out of the way.
(4) Remove the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
(5) Disconnect the battery temperature sensor
from the battery tray.
(6) Remove the four upper shock mounting nuts.
(7) Raise and support the vehicle.(8) Remove the left tire and wheel assembly.
(9) Remove the lower bolt at the lower control
securing the clevis bracket.
(10) Remove the stabilizer link (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER LINK - REMOVAL).
(11) Remove the lower ball joint nut.
(12) Seperate the lower ball joint from the lower
control arm using tool C-4150A.
(13) Rotate the lower control arm downward to
allow access.
(14) Remove the clevis bracket at the shock.
(15) Remove the shock assembly from the vehicle.
(Fig. 4)
(16) Remove the spring from the shock (if needed).
REMOVAL - RIGHT SIDE
(1) Remove the air box (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
REMOVAL).
(2) Remove the two cruise control servo mounting
nuts.
(3) Remove the upper shock mounting nuts.
(4) Raise and support the vehicle.
(5) Remove the right side tire assembly.
(6) Remove the lower bolt at the lower control
securing the clevis bracket.
(7) Remove the stabilizer link (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER LINK - REMOVAL).
(8) Remove the lower ball joint nut.
(9) Seperate the lower ball joint from the lower
control arm using tool C-4150A.
(10) Rotate the lower control arm downward to
allow access.
Fig. 3 LOWER CONTROL ARM
1 - FRONT CAM BOLT
2 - OUTER TIE ROD END
3 - LOWER BALL JOINT NUT
4 - LOWER CONTROL ARM
5 - REAR CAM BOLT
Fig. 4 SHOCK ASSEMBLY
1 - SPRING
2 - JOUNCE BUMPER
3 - SHOCK
4 - UPPER CONTROL ARM
KJFRONT 2 - 11
LOWER CONTROL ARM (Continued)

(11) Remove the clevis bracket at the shock. (Fig.
5)
(12) Remove the shock assembly from the vehicle.
(Fig. 5)
(13) Remove the spring from the shock (if needed).
(Refer to 2 - SUSPENSION/FRONT/SPRING -
REMOVAL).
INSTALLATION
INSTALLATION - LEFT SIDE
(1) Install the spring to the shock (if removed).
(2) Install the shock assembly to the vehicle.
(3) Install the four upper shock mounting nuts.
Tighten the nuts to 108 N´m (80 ft.lbs.).
(4) Install the clevis bracket at the shock. (Refer to
2 - SUSPENSION/FRONT/CLEVIS BRACKET -
INSTALLATION). Tighten the bolt to 88 N´m (65
ft.lbs.).
(5) Raise the lower control into place and recon-
nect the lower ball joint nut. Tighten the nut to 81
N´m (60 ft.lbs.).
(6) Install the clevis bracket at the lower control
arm. (Refer to 2 - SUSPENSION/FRONT/CLEVIS
BRACKET - INSTALLATION). Tighten the bolt to
150 N´m (110 ft.lbs.).(7) Install the lower stabilizer link at the lower
control arm. Tighten the bolt to 136 N´m (100 ft.lbs.)
(Refer to 2 - SUSPENSION/FRONT/STABILIZER
LINK - INSTALLATION).
(8) Install the left tire and wheel assembly. (Refer
to 22 - TIRES/WHEELS/WHEELS - STANDARD
PROCEDURE).
(9) Lower the vehicle.
(10) Reconnect the battery temperature sensor.
(11) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
(12) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(13) Reconnect the battery cables.
INSTALLATION - RIGHT SIDE
(1) Install the spring to the shock (if removed).
(Refer to 2 - SUSPENSION/FRONT/SPRING -
INSTALLATION).
(2) Install the shock assembly to the vehicle.
(3) Install the four upper shock mounting nuts.
Tighten the nuts to 108 N´m (80 ft.lbs.).
(4) Install the clevis bracket at the shock. (Refer to
2 - SUSPENSION/FRONT/CLEVIS BRACKET -
INSTALLATION). Tighten the bolt to 88 N´m (65
ft.lbs.).
(5) Raise the lower control into place and recon-
nect the lower ball joint nut. Tighten the nut to 81
N´m (60 ft.lbs.).
(6) Install the clevis bracket at the lower control
arm. (Refer to 2 - SUSPENSION/FRONT/CLEVIS
BRACKET - INSTALLATION). Tighten the bolt to
150 N´m (110 ft.lbs.).
(7) Install the lower stabilizer link at the lower
control arm. Tighten the bolt to 136 N´m (100 ft.lbs.)
(Refer to 2 - SUSPENSION/FRONT/STABILIZER
LINK - INSTALLATION).
(8) Install the right tire and wheel assembly.
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(9) Lower the vehicle.
(10) Install the cruise control servo mounting nuts.
(11) Install the airbox (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
INSTALLATION).
Fig. 5 SHOCK & CLEVIS ASSEMBLY
1 - FRONT CRADLE
2 - SPRING & SHOCK ASSEMBLY
3 - STEERING KNUCKLE
4 - CLEVIS BRACKET
5 - LOWER CONTROL ARM
2 - 12 FRONTKJ
SHOCK (Continued)

SPRING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the shock. Refer to the proper side
shock removal procedure being worked on. (Refer to 2
- SUSPENSION/FRONT/SHOCK - REMOVAL).
(4) Secure the shock assembly into a Pentastar
Service Equipment W-7200 Spring compressor. (Fig.
6)
(5) Compress the spring.
(6) Remove the shock mount nut.
(7) Remove the shock from the spring compressor.
(8) Transfer the necessary parts to the type of
repair being done (Insulator, Spring, shock and
mount).
INSTALLATION
(1) Install the shock to the spring and spring com-
pressor, After the transfer of the necessary parts to
the type of repair being done (Insulator, Spring,
shock and mount).
(2) Install the shock mounting nut. Tighten the
bolt to 41 N´m (30 ft.lbs.).
(3) Loosen the compressed spring.
(4) Remove the shock assembly from the spring
compressor.
(5) Install the shock to the vehicle. (Refer to 2 -
SUSPENSION/FRONT/SHOCK - INSTALLATION).
(6) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(7) Remove the support and lower the vehicle.
CLEVIS BRACKET
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the lower clevis bolt at the lower con-
trol arm. (Fig. 7)
(4) Remove the upper clevis bolt at the shock. (Fig.
7)
(5) Remove the lower stabilizer link bolt at the
lower control arm.
(6) Remove the lower ball joint nut.
(7) Seperate the lower ball joint from the lower
control arm using tool C-4150A.
(8) Swing the lower control arm downward to
allow clearence to remove the clevis braket.
(9) Remove the clevis bracket from the vehicle.
INSTALLATION
(1) Install the clevis bracket to the shock. Tighten
the bolt to 136 N´m (100 ft.lbs.) (Fig. 7).
(2) Raise the lower control arm to the lower ball
joint.
(3) Install the nut to the lower ball joint. Tighten
the nut to 81 N´m (60 ft.lbs.).
(4) Install the clevis bracket to the lower control
arm. Tighten the bolt to 150 N´m (110 ft.lbs.).
(5) Install the lower stabilizer link bolt at the
lower control arm. Tighten the bolt to 115 N´m (85
ft.lbs.).
(6) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(7) Lower the vehicle.
Fig. 6 SPRING COMPRESSOR
1 - SPRING COMPRESSOR
2 - SPRING
Fig. 7 CLEVIS BRACKET
1 - UPPER BOLT
2 - CLEVIS BRACKET
3 - LOWER BOLT
KJFRONT 2 - 13

REMOVAL - LEFT SIDE
(1) Raise and support the vehicle.
(2) Remove the left side tire and wheel assembly.
(3) Remove the upper ball joint nut.
(4) Separate the upper ball joint from the steering
knuckle using tool C-4150A.
(5) Lower the vehicle.
(6) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(7) Unclip the power center and move it to the side
out of the way.
(8) Remove the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
(9) Disconnect the battery temperature sensor
from the battery tray.
(10) Remove the upper control arm rear bolt by
using a ratchet and extension under the steering
shaft and positioned by the power steering reservoir.
(Fig. 10)
(11) Remove the upper control arm front bolt.
(12) Remove the upper control arm from the vehi-
cle.
INSTALLATION
INSTALLATION - RIGHT SIDE
(1) Install the upper control arm to the vehicle.
(2) Install the upper control arm front bolt.
Tighten the bolt to 122 N´m (90 ft.lbs.).
(3) Install the upper control arm rear bolt. Tighten
the bolt to 122 N´m (90 ft.lbs.).
(4) Install the cruise control servo mounting nuts.(5) Install the air box (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
INSTALLATION).
(6) Install the upper ball joint nut. Tighten the nut
to 81 N´m (60 ft.lbs.).
(7) Install the right side tire and wheel assembly.
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(8) Lower the vehicle.
(9) Set the toe and center the steering wheel
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
INSTALLATION - LEFT SIDE
(1) Install the upper control arm to the vehicle.
(2) Install the upper control arm front bolt (Fig.
11). Tighten the bolt to 122 N´m (90 ft.lbs.).
(3) Install the upper control arm rear bolt (Fig.
11). Tighten the bolt to 122 N´m (90 ft.lbs.).
(4) Reconnect the battery temperature sensor to
the battery tray.
(5) Install the battery tray (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - INSTALLATION).
(6) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(7) Reclip and mount the power center.
(8) Install the upper ball joint nut (Fig. 11).
Tighten the nut to 81 N´m (60 ft.lbs.).
(9) Install the left side tire and wheel assembly.
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(10) Lower the vehicle.
(11) Set the toe and center the steering wheel
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
Fig. 10 REAR BOLT
1 - STEERING SHAFT
2 - REAR BOLT
3 - RATCHET WITH AN EXTENSION
Fig. 11 UPPER CONTROL ARM
KJFRONT 2 - 15
UPPER CONTROL ARM (Continued)

DIAGNOSIS AND TESTING - REAR SUSPENSION
CONDITION POSSIBLE CAUSES CORRECTION
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.
2. Loose, worn or bent suspension
components.2. Inspect, tighten or replace components
as necessary.
3. Tire pressure. 3. Adjust tire pressure.
VEHICLE PULLS TO ONE
SIDE1. Weak or broken spring. 1. Replace spring.
2. Alignment. 2. Align vehicle to specifications.
3.Tires. 3. Replace tires.
4. Brakes. 4. Repair as necassary.
KNOCKING, RATTLING
OR SQUEAKING1. Worn shock bushings. 1. Replace shock.
2. Loose shock mounting. 2. Tighten to specifications.
3. Shock valve. 3. Replace shock.
4. Loose upper ball joint. 4. Replace ball joint.
5. Loose, worn or bent suspension
components.5. Inspect, tighten or replace components
as necessary.
IMPROPER TRACKING 1. Loose, worn or bent suspension
components.1. Inspect, tighten or replace components
as necessary.
2. Bent axle. 2.Replace axle.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber Upper Nut 108 80 Ð
Shock Absorber Lower Nut 115 85 Ð
Suspension Arm Upper Ball Joint Nut 95 70 Ð
Suspension Arm Upper Frame Bolts 100 74 Ð
Rear Upper Ball Joint Bracket Bolts 136 100 Ð
Suspension Arms Lower Body/Axle Bracket Nut 163 120 Ð
Suspension Arms Lower Frame Bracket Nut 163 120 Ð
Stabilizer Bar Bolts 99 73 Ð
KJREAR 2 - 17
REAR (Continued)

SPONGY PEDAL
A spongy pedal is most often caused by air in the
system. However, thin brake drums or substandard
brake lines and hoses can also cause a spongy pedal.
The proper course of action is to bleed the system,
and replace thin drums and substandard quality
brake hoses if suspected.
HARD PEDAL OR HIGH PEDAL EFFORT
A hard pedal or high pedal effort may be due to
lining that is water soaked, contaminated, glazed, or
badly worn. The power booster or check valve could
also be faulty.
PEDAL PULSATION
Pedal pulsation is caused by components that are
loose, or beyond tolerance limits.
The primary cause of pulsation are disc brake
rotors with excessive lateral runout or thickness vari-
ation, or out of round brake drums. Other causes are
loose wheel bearings or calipers and worn, damaged
tires.
NOTE: Some pedal pulsation may be felt during
ABS activation.
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.
Drag is a product of incomplete brake shoe release.
Drag can be minor or severe enough to overheat the
linings, rotors and drums.
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
severe cases, the lining may generate smoke as it
chars from overheating.
Common causes of brake drag are:
²Seized or improperly adjusted parking brake
cables.
²Loose/worn wheel bearing.
²Seized caliper or wheel cylinder piston.
²Caliper binding on corroded bushings or rusted
slide surfaces.
²Loose caliper mounting.
²Drum brake shoes binding on worn/damaged
support plates.
²Mis-assembled components.²Long booster output rod.
If brake drag occurs at all wheels, the problem
may be related to a blocked master cylinder return
port, or faulty power booster (binds-does not release).
BRAKE FADE
Brake fade is usually a product of overheating
caused by brake drag. However, brake overheating
and resulting 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
mountain roads. Refer to the Brake Drag information
in this section for causes.
BRAKE PULL
Front brake pull condition could result from:
²Contaminated lining in one caliper
²Seized caliper piston
²Binding caliper
²Loose caliper
²Rusty caliper slide surfaces
²Improper brake shoes
²Damaged rotor
A worn, damaged wheel bearing or suspension
component are further causes of pull. A damaged
front tire (bruised, ply separation) can also cause
pull.
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 one of the brake units.
As the dragging brake overheats, efficiency is so
reduced that fade occurs. Since the opposite brake
unit is still functioning normally, its braking effect is
magnified. This causes pull to switch direction in
favor of the normally functioning brake unit.
An additional point when diagnosing a change in
pull condition concerns brake cool down. Remember
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 OR PULL
Rear grab or pull is usually caused by improperly
adjusted or seized parking brake cables, contami-
nated lining, bent or binding shoes and support
plates, or improperly assembled components. This is
particularly true when only one rear wheel is
involved. However, when both rear wheels are
affected, the master cylinder or proportioning valve
could be at fault.
5 - 4 BRAKES - BASEKJ
BRAKES - BASE (Continued)

BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP
WATER PUDDLES
This condition is generally caused by water soaked
lining. If the lining is only wet, it can be dried by
driving with the brakes very lightly applied for a
mile or two. However, if the lining is both soaked and
dirt contaminated, cleaning and/or replacement will
be necessary.
BRAKE LINING CONTAMINATION
Brake lining contamination is mostly a product of
leaking calipers or wheel cylinders, worn seals, driv-
ing through deep water puddles, or lining that has
become covered with grease and grit during repair.
Contaminated lining should be replaced to avoid fur-
ther brake problems.
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
produce a grab-like condition as the tire loses and
recovers traction. Flat-spotted tires can cause vibra-
tion and generate shudder during brake operation. A
tire with internal damage such as a severe bruise,
cut, or ply separation can cause pull and vibration.
BRAKE NOISES
Some brake noise is common with rear drum
brakes and on some disc brakes during the first few
stops after a vehicle has been parked overnight or
stored. This is primarily due to the formation of trace
corrosion (light rust) on metal surfaces. This light
corrosion is typically cleared from the metal surfaces
after a few brake applications causing the noise to
subside.
BRAKE SQUEAK/SQUEAL
Brake squeak or squeal may be due to linings that
are wet or contaminated with brake fluid, grease, or
oil. Glazed linings and rotors with hard spots can
also contribute to squeak. Dirt and foreign material
embedded in the brake lining will also cause squeak/
squeal.
A very loud squeak or squeal is frequently a sign of
severely worn brake lining. If the lining has worn
through to the brake shoes in spots, metal-to-metal
contact occurs. If the condition is allowed to continue,
rotors and drums can become so scored that replace-
ment is necessary.
BRAKE CHATTER
Brake chatter is usually caused by loose or worn
components, or glazed/burnt lining. Rotors with hard
spots can also contribute to chatter. Additional causesof chatter are out-of-tolerance rotors, brake lining not
securely attached to the shoes, loose wheel bearings
and contaminated brake lining.
THUMP/CLUNK NOISE
Thumping or clunk noises during braking are fre-
quentlynotcaused by brake components. In many
cases, such noises are caused by loose or damaged
steering, suspension, or engine components. However,
calipers that bind on the slide surfaces can generate
a thump or clunk noise. In addition, worn out,
improperly adjusted, or improperly assembled rear
brake shoes can also produce a thump noise.
STANDARD PROCEDURE
STANDARD PROCEDURE - PRESSURE
BLEEDING
Use Mopar brake fluid, or an equivalent quality
fluid meeting SAE J1703-F and DOT 3 standards
only. Use fresh, clean fluid from a sealed container at
all times.
Do not pump the brake pedal at any time while
bleeding. Air in the system will be compressed into
small bubbles that are distributed throughout the
hydraulic system. This will make additional bleeding
operations necessary.
Do not allow the master cylinder to run out of fluid
during bleed operations. An empty cylinder will allow
additional air to be drawn into the system. Check the
cylinder fluid level frequently and add fluid as
needed.
Bleed only one brake component at a time in the
following sequence:
²Master Cylinder
²Combination Valve
²Right Rear Wheel
²Left Rear Wheel
²Right Front Wheel
²Left Front Wheel
Follow the manufacturers instructions carefully
when using pressure equipment. Do not exceed the
tank manufacturers pressure recommendations. Gen-
erally, a tank pressure of 15-20 psi is sufficient for
bleeding.
Fill the bleeder tank with recommended fluid and
purge air from the tank lines before bleeding.
Do not pressure bleed without a proper master cyl-
inder adapter. The wrong adapter can lead to leak-
age, or drawing air back into the system. Use
adapter provided with the equipment or Adapter
6921.
KJBRAKES - BASE 5 - 5
BRAKES - BASE (Continued)