2000 Jeep Grand Cherokee Service Manual (Brakes)
2000 Jeep Grand Cherokee Service Manual (Brakes)
2000 Jeep Grand Cherokee Service Manual (Brakes)
BRAKES
TABLE OF CONTENTS
page page
TABLE OF CONTENTS
page page
ELECTRONIC BRAKE DISTRIBUTION Two push rods are used in the booster. The pri-
mary push rod connects the booster to the brake
DESCRIPTION pedal. The secondary push rod connects the booster
The electronic brake distribution (EBD) functions to the master cylinder to stroke the cylinder pistons.
like a rear proportioning valve. The EBD system uses
the ABS system to control the slip of the rear wheels OPERATION
in partial braking range. The braking force of the The atmospheric inlet valve is opened and closed
rear wheels is controlled electronically by using the by the primary push rod. Booster vacuum supply is
inlet and outlet valves located in the HCU. through a hose attached to an intake manifold fitting
at one end and to the booster check valve at the
OPERATION other. The vacuum check valve in the booster housing
Upon entry into EBD the inlet valve for the rear is a one-way device that prevents vacuum leak back.
brake circuit is switched on so that the fluid supply Power assist is generated by utilizing the pressure
from the master cylinder is shut off. In order to differential between normal atmospheric pressure
decrease the rear brake pressure the outlet valve for and a vacuum. The vacuum needed for booster oper-
the rear brake circuit is pulsed. This allows fluid to ation is taken directly from the engine intake mani-
enter the low pressure accumulator (LPA) in the fold. The entry point for atmospheric pressure is
HCU resulting in a drop in fluid pressure to the rear through a filter and inlet valve at the rear of the
brakes. In order to increase the rear brake pressure housing (Fig. 1).
the outlet valve is switched off and the inlet valve is The chamber areas forward of the booster dia-
pulsed. This increases the pressure to the rear phragms are exposed to vacuum from the intake
brakes. This will continue until the required slip dif- manifold. The chamber areas to the rear of the dia-
ference is obtained. At the end of EBD braking (no phragms, are exposed to normal atmospheric pres-
brake application) the fluid in the LPA drains back to sure of 101.3 kilopascals (14.7 pounds/square in.).
the master cylinder by switching on the outlet valve Brake pedal application causes the primary push
and draining through the inlet valve check valve. At rod to open the atmospheric inlet valve. This exposes
the same time the inlet valve is switched on to pre- the area behind the diaphragms to atmospheric pres-
vent a hydraulic short circiut in case of another sure. The resulting pressure differential provides the
brake application. extra apply force for power assist.
The EBD will remain functional during many ABS The booster check valve, check valve grommet and
fault modes. If the red and amber warning lamps are booster seals are serviceable.
illuminated the EBD may have a fault.
MASTER CYLINDER
RED BRAKE WARNING LAMP
DESCRIPTION
DESCRIPTION The master cylinder body is made of aluminum
A red warning lamp is used for the service brake and contains a primary and secondary piston assem-
portion of the hydraulic system. The lamp is located bly. The cylinder body including the piston assem-
in the instrument cluster. blies are not serviceable. If diagnosis indicates an
internal problem with the cylinder body, it must be
OPERATION replaced as an assembly. The master cylinder has a
The lamp is turned on momentarily when the igni- removable reservoir and fluid level indicator. The res-
tion switch is turn to the on position. This is a self ervoir, reservoir grommets, reservoir cap and fluid
test to verify the lamp is operational. level switch are the only replaceable parts on the
The red warning light alerts the driver if the fluid master cylinder.
level is low or the parking brakes are applied. A red
warning lamp with an amber warning lamp may OPERATION
indicate a electronic brake distribution fault. The master cylinder bore contains a primary and
secondary piston. The primary piston supplies
POWER BRAKE BOOSTER hydraulic pressure to the front brakes. The secondary
piston supplies hydraulic pressure to the rear brakes.
DESCRIPTION The master cylinder reservoir stores reserve brake
The booster assembly consists of a housing divided fluid for the hydraulic brake circuits.
into separate chambers by two internal diaphragms.
The outer edge of each diaphragm is attached to the
booster housing.
5-4 BRAKES WJ
DESCRIPTION AND OPERATION (Continued)
FRONT DISC BRAKES means pressure exerted against the caliper pistons
and within the caliper bores will be equal (Fig. 2).
DESCRIPTION Fluid pressure applied to the pistons is transmit-
The calipers are twin piston type. The calipers are ted directly to the inboard brake shoe. This forces the
free to slide laterally on the anchor, this allows con- shoe lining against the inner surface of the disc
tinuous compensation for lining wear. brake rotor. At the same time, fluid pressure within
the piston bores forces the caliper to slide inward on
OPERATION the slide pins. This action brings the outboard brake
When the brakes are applied fluid pressure is shoe lining into contact with the outer surface of the
exerted against the caliper pistons. The fluid pres- disc brake rotor.
sure is exerted equally and in all directions. This
WJ BRAKES 5-5
DESCRIPTION AND OPERATION (Continued)
SERVICE PROCEDURES
BRAKE FLUID LEVEL
Always clean the master cylinder reservoir and cap
before adding fluid. This will prevent dirt from fall-
ing in the reservoir and contaminating the brake
fluid.
Fig. 11 Master Cylinder Bleeding
The reservoir has a MIN and a MAX mark on the
1 – BLEEDING TUBES
side (Fig. 10) fill to the MAX mark. 2 – RESERVOIR
INSTALLATION
(1) Install the sensor with a new o-ring into the
reservoir until the locking tabs are engaged.
(2) Install the wire connector to the fluid level sen-
sor.
Fig. 19 Pedal Bushings (4) Pull the reservoir straight up out of the cylin-
1 – BUSHING der.
2 – BUSHING (5) Remove and discard grommets from the cylin-
3 – SHAFT NUT der body.
4 – PEDAL SHAFT
INSTALLATION
(2) From the same side of the master cylinder res- (1) Lubricate new grommets with clean brake
ervoir release the sensor locking taps with a small fluid. Install new grommets into the cylinder body.
screw driver.
WJ BRAKES 5 - 17
REMOVAL AND INSTALLATION (Continued)
CAUTION: Do not use tools to install the grom- (1) Have an assistant depress the brake pedal
mets. Tools may cut, or tear the grommets. Install while guiding the master cylinder on the booster rod
the grommets using finger pressure only. and mounting studs.
(2) Start reservoir in grommets then press the res- CAUTION: Do not depress brake pedal too hard
ervoir straight down to seat the reservoir into the and ensure the booster rod is in the master cylinder
cylinder grommets. piston or booster/master cylinder damage will
occur.
CAUTION: Do not rock the reservoir during instal-
lation. (2) Install master cylinder mounting nuts and
tighten nuts to 25 N·m (18 lb. lbs.).
(3) Verify retaining tabs are seated.
(4) Install the wire connector to the brake fluid NOTE: Use original or factory replacement nuts
level sensor. only.
(5) Fill master cylinder.
(3) Install brake lines and tighten to 16 N·m (144
MASTER CYLINDER in. lbs.).
(4) Install fluid level sensor connector.
REMOVAL (5) Fill and bleed brake system.
(1) Remove the wire connector from the brake fluid
level sensor. POWER BRAKE BOOSTER
(2) Remove brake lines from master cylinder.
(3) Remove nuts that attach master cylinder to REMOVAL
booster studs (Fig. 21). (1) Remove the master cylinder.
(4) Remove master cylinder from booster. (2) Disconnect vacuum hose at booster check valve.
(3) Remove retainer clip (Fig. 22) that holds
booster push rod on pedal pin. Then slide push rod
off pin.
INSTALLATION
(1) Install the inboard brake shoe onto the caliper
(Fig. 31).
(2) Install the outboard shoe onto the caliper
anchor (Fig. 32).
(3) Lubricate the slide pins and slide pin bushings
with Dow Corningt grease G807 or the grease pro-
vided with the brake shoes. Fig. 33 Caliper Anchor Bolts
(4) Install caliper on the caliper anchor. 1 – KNUCKLE
(5) Install the caliper slide pin and tighten to 2 – ANCHOR
29-41 N·m (21-30 ft. lbs.). 3 – ANCHOR BOLTS
(6) Install the caliper slide pin bushing caps. 4 – ROTOR
(7) Install the caliper support spring in the top
end of the caliper and under the anchor. Then install
(4) Secure caliper anchor assembly to nearby sus-
other end into the lower caliper hole. Hold the spring
pension part with a wire. Do not allow brake hose
into the caliper hole with your thumb while prying
to support caliper weight.
the end of the spring out and down under the anchor
(5) Mark the rotor and hub/bearing to maintain
with a screw drive.
original orientation. Remove retainers securing rotor
(8) Install wheel and tire assembly.
to hub studs.
(9) Remove support and lower vehicle.
(6) Remove rotor from hub/bearing.
(10) Pump brake pedal until caliper pistons and
brake shoes are seated and a firm brake pedal is INSTALLATION
obtained.
(11) Fill brake fluid. NOTE: If a new rotor is installed it must be match
mounted to the hub/bearing.
INSTALLATION (2) Lubricate the slide pins and slide pin bushings
with Dow Corningt grease G807 or the grease pro-
(1) Install the inboard brake shoe (Fig. 37).
vided with the caliper.
WJ BRAKES 5 - 23
REMOVAL AND INSTALLATION (Continued)
(3) Install the caliper on the anchor. (5) Remove the caliper support spring by prying
(4) Install the caliper slide pin and tighten to the spring out of the caliper (Fig. 39).
29-41 N·m (21-30 ft. lbs.).
(5) Install the caliper slide pin caps.
(6) Install the caliper support spring in the top
end of the caliper and under the anchor. Then install
other end into the lower caliper hole. Hold the spring
into the caliper hole with your thumb while prying
the end of the spring out and down under the anchor
with a screw drive.
(7) Install brake hose to caliper with new gasket
washers and tighten banjo bolt to 31 N·m (23 ft. lbs.).
INSTALLATION
(1) Install the inboard brake shoe onto the caliper
(Fig. 41).
(2) Install the outboard brake shoe onto the caliper
anchor (Fig. 42).
(3) Lubricate the slide pins and slide pin bushings
with Dow Corningt grease G807 or the grease pro-
vided with the brake shoes.
(4) Install caliper on the anchor.
(5) Install the caliper slide pin and tighten to
29-41 N·m (21-30 ft. lbs.). Fig. 42 Outboard Brake Shoe
(6) Install the caliper slide pin bushing caps. 1 – OUTBOARD BRAKE SHOE
(7) Install the caliper support spring in the top 2 – CALIPER ANCHOR
end of the caliper and under the anchor. Then install 3 – ROTOR
other end into the lower caliper hole. Hold the spring
into the caliper hole with your thumb while prying (9) Remove support and lower vehicle.
the end of the spring out and down under the anchor
with a screw drive.
(8) Install wheel and tire assembly.
WJ BRAKES 5 - 25
REMOVAL AND INSTALLATION (Continued)
(10) Pump brake pedal until caliper piston and PARKING BRAKE LEVER
brake shoes are seated and a firm brake pedal is
obtained. REMOVAL
(11) Fill brake fluid level if necessary. (1) Remove center console, refer to Group 23 Body.
(2) Lift up rear seat and carpet covering the park-
REAR DISC BRAKE ROTOR ing brake cables.
(3) Place a screw driver through the front cable
REMOVAL eyelet (Fig. 44) and pry back on the front cable.
(1) Raise and support the vehicle.
(2) Remove wheel and tire assembly.
(3) Remove the caliper anchor bolts (Fig. 43).
INSTALLATION
(1) Install rotor on axle studs.
(2) Install the caliper anchor assembly.
(3) Install anchor bolts and tighten to 90-115 N·m
(66-85 ft. lbs.).
(4) Install wheel and tire assembly.
(5) Remove support and lower the vehicle.
(6) Pump brake pedal until caliper pistons and Fig. 45 Lock Out Spring
brake shoes are seated. 1 – LOCK OUT SPRING
5 - 26 BRAKES WJ
REMOVAL AND INSTALLATION (Continued)
(5) Disconnect parking brake switch wiring con- INSTALLATION
nector. (1) Install the lever assembly on the mounting
(6) Disengage front cable end from parking brake studs while feeding the front cable into the lever
lever. bracket.
(7) Compress the cable retainer with a 13 mm (2) Install the console bracket (Fig. 47) and mount-
wrench (Fig. 46) and remove the cable from the park- ing nuts.
ing brake lever bracket. (3) Engage the front cable end to the lever.
(4) Connect parking brake switch wire connector.
(5) Pull on the lever to release the lock out spring.
(6) Install center console, refer to Group 23 Body.
(7) Fold down the rear carpet cover and rear seat.
(6) Disengage front cable end from the parking (3) Engage front cable ends to the parking brake
brake lever. lever and equalizer.
(7) Remove the front carpet, refer to Group 23 (4) Install the front carpet, refer to Group 23 Body.
Body. (5) Pull on the lever to release the lock out spring.
(8) Remove front cable retainer nuts (Fig. 51) from (6) Install center console, refer to Group 23 Body.
the floor pan. (7) Fold down the rear carpet cover and rear seat.
(9) Compress the cable retainers with a 13 mm
wrench (Fig. 52). Remove the cable from parking REAR PARKING BRAKE CABLES
brake lever bracket and equalizer bracket.
REMOVAL
INSTALLATION (1) Remove center console, refer to Group 23 Body.
(1) Install cable into the parking brake lever (2) Lift up rear seat and carpet covering the park-
bracket and equalizer bracket. ing brake cables.
(2) Install front cable to the floor pan and install (3) Place a screw driver through the front cable
retainer nuts. eyelet (Fig. 53) and pry back on the front cable.
5 - 28 BRAKES WJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Install the cables through the caliper anchor
mount. Then push the end of cable strand in to
engage the cable end to the parking brake actuator.
(2) Feed the other end of the cables through the
body and into the equalizer bracket (Fig. 58).
ANTILOCK BRAKES
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION kph (18 mph). During the dynamic check, the CAB
briefly cycles the pump and solenoids to verify oper-
ANTILOCK BRAKE SYSTEM ation.
If an ABS component exhibits a fault during ini-
DESCRIPTION tialization, the CAB illuminates the amber warning
The purpose of the antilock system is to prevent light and registers a fault code in the microprocessor
wheel lockup during periods of high wheel slip. Pre- memory.
venting lockup helps maintain vehicle braking action
ANTILOCK BRAKING
and steering control.
The hydraulic system is a three channel design. The antilock system prevents lockup during high
The front brakes are controlled individually and the slip conditions by modulating fluid apply pressure to
rear brakes in tandem. the wheel brake units.
The ABS electrical system is separate from other Brake fluid apply pressure is modulated according
vehicle electrical circuits. A separate controller oper- to wheel speed, degree of slip and rate of decelera-
ates the system. tion. A sensor at each wheel converts wheel speed
into electrical signals. These signals are transmitted
OPERATION to the CAB for processing and determination of
The antilock CAB activates the system whenever wheel slip and deceleration rate.
sensor signals indicate periods of high wheel slip. The ABS system has three fluid pressure control
High wheel slip can be described as the point where channels. The front brakes are controlled separately
wheel rotation begins approaching 20 to 30 percent of and the rear brakes in tandem. A speed sensor input
actual vehicle speed during braking. Periods of high signal indicating a high slip condition activates the
wheel slip occur when brake stops involve high pedal CAB antilock program.
pressure and rate of vehicle deceleration. Two solenoid valves are used in each antilock con-
Battery voltage is supplied to the CAB ignition ter- trol channel. The valves are all located within the
minal when the ignition switch is turned to Run posi- HCU valve body and work in pairs to either increase,
tion. The CAB performs a system initialization hold, or decrease apply pressure as needed in the
procedure at this point. Initialization consists of a individual control channels.
static and dynamic self check of system electrical The solenoid valves are not static during antilock
components. braking. They are cycled continuously to modulate
The static check occurs after the ignition switch is pressure. Solenoid cycle time in antilock mode can be
turned to Run position. The dynamic check occurs measured in milliseconds.
when vehicle road speed reaches approximately 30
WJ BRAKES 5 - 39
DESCRIPTION AND OPERATION (Continued)
OPERATION
Upon entry into EBD the inlet valve for the rear
brake circuit is switched on so that the fluid supply
from the master cylinder is shut off. In order to
decrease the rear brake pressure the outlet valve for
the rear brake circuit is pulsed. This allows fluid to
Fig. 1 Controller Antilock Brakes
enter the low pressure accumulator (LPA) in the
1 – HCU
HCU resulting in a drop in fluid pressure to the rear 2 – MOTOR
brakes. In order to increase the rear brake pressure 3 – CAB
the outlet valve is switched off and the inlet valve is
pulsed. This increases the pressure to the rear
brakes. This will continue until the required slip dif- HYDRAULIC CONTROL UNIT
ference is obtained. At the end of EBD braking (no
brake application) the fluid in the LPA drains back to DESCRIPTION
the master cylinder by switching on the outlet valve The HCU consists of a valve body, pump motor,
and draining through the inlet valve check valve. At and wire harness (Fig. 1).
the same time the inlet valve is switched on to pre-
vent a hydraulic short circiut in case of another OPERATION
brake application. Accumulators in the valve body store extra fluid
The EBD will remain functional during many ABS released to the system for ABS mode operation. The
fault modes. If the red and amber warning lamps are pump is used to clear the accumulator of brake fluid
illuminated the EBD may have a fault. and is operated by a DC type motor. The motor is
controlled by the CAB.
CONTROLLER ANTILOCK BRAKES The valves modulate brake pressure during
antilock braking and are controlled by the CAB.
DESCRIPTION The HCU provides three channel pressure control
The CAB is mounted to the HCU and operates the to the front and rear brakes. One channel controls
ABS system (Fig. 1) separate from other vehicle elec- the rear wheel brakes in tandem. The two remaining
trical circuits. channels control the front wheel brakes individually.
During antilock braking, the solenoid valves are
OPERATION opened and closed as needed. The valves are not
The CAB voltage source is through the ignition static. They are cycled rapidly and continuously to
switch in the RUN position. The CAB contains dual modulate pressure and control wheel slip and decel-
microprocessors. A logic block in each microprocessor eration.
receives identical sensor signals. These signals are During normal braking, the HCU solenoid valves
processed and compared simultaneously. The CAB and pump are not activated. The master cylinder and
contains a self check program that illuminates the power booster operate the same as a vehicle without
ABS warning light when a system fault is detected. an ABS brake system.
Faults are stored in a diagnostic program memory During antilock braking, solenoid valve pressure
and are accessible with the DRB scan tool. ABS modulation occurs in three stages, pressure increase,
faults remain in memory until cleared, or until after pressure hold, and pressure decrease. The valves are
the vehicle is started approximately 50 times. Stored all contained in the valve body portion of the HCU.
faults are not erased if the battery is disconnected.
PRESSURE DECREASE
The outlet valve is opened and the inlet valve is
closed during the pressure decrease cycle.
5 - 40 BRAKES WJ
DESCRIPTION AND OPERATION (Continued)
A pressure decrease cycle is initiated when speed
sensor signals indicate high wheel slip at one or
more wheels. At this point, the CAB closes the inlet
then opens the outlet valve, which also opens the
return circuit to the accumulators. Fluid pressure is
allowed to bleed off (decrease) as needed to prevent
wheel lock.
Once the period of high wheel slip has ended, the
CAB closes the outlet valve and begins a pressure
increase or hold cycle as needed.
PRESSURE HOLD
Both solenoid valves are closed in the pressure
hold cycle. Fluid apply pressure in the control chan-
nel is maintained at a constant rate. The CAB main-
tains the hold cycle until sensor inputs indicate a
pressure change is necessary. Fig. 2 G-Switch
1 – SWITCH PART NUMBER
PRESSURE INCREASE 2 – ARROW INDICATES FRONT OF SWITCH FOR PROPER
The inlet valve is open and the outlet valve is MOUNTING
closed during the pressure increase cycle. The pres-
sure increase cycle is used to counteract unequal OPERATION
wheel speeds. This cycle controls re-application of The switch is monitored by the CAB at all times.
fluid apply pressure due to changing road surfaces or The switch contains three mercury switches which
wheel speed. monitor vehicle deceleration rates (G-force). Sudden
changes in deceleration rates trigger the switch,
WHEEL SPEED SENSORS AND TONE WHEEL sending a signal to the CAB.
INSTALLATION
CAUTION: The mercury switch (inside the
G-Switch), will not function properly if the switch is
installed incorrectly. Verify that the switch locating
arrow is pointing to the front of the vehicle (Fig.
14).
G-SWITCH
Fig. 14 G-Switch
REMOVAL 1 – SWITCH PART NUMBER
2 – ARROW INDICATES FRONT OF SWITCH FOR PROPER
(1) Fold the rear seat bottom assembly up for MOUNTING
access to the switch.
(2) Lift up the carpeting and disconnect switch
harness (Fig. 13).
(3) Remove the switch mounting bolts and remove
the switch.
WJ BRAKES 5 - 45
REMOVAL AND INSTALLATION (Continued)
(1) Note position of locating arrow on switch. Posi- SPECIFICATIONS
tion switch so arrow faces forward.
(2) Install the switch and tighten mounting bolts TORQUE CHART
to 5.6 N·m (50 in. lbs.).
(3) Connect harness to switch. Be sure harness
DESCRIPTION TORQUE
connector is firmly seated.
G-Sensor
(4) Place the carpet in position and fold the rear
seat back down. Sensor Bolt . . . . . . . . . . . . . . 5.6 N·m (50 in. lbs.)
Hydraulic Control Unit/Controller Antilock
Brakes
Mounting Bolts . . . . . . . . . . . . 12 N·m (9 ft. lbs.)
Brake Lines . . . . . . . . . . . . . 16 N·m (144 in. lbs.)
CAB Screws . . . . . . . . . . . . . 1.8 N·m (16 in. lbs.)
Wheel Speed Sensors
Front Sensor Bolt . . 12-14 N·m (106-124 in. lbs.)
Rear Sensor Bolt . . . 12-14 N·m (106-124 in. lbs.)