exj 5a, JEEP Manuals, Electronic Service Manual (jeep cherokee xj do 2000)
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XJ
BRAKES
5 - 1
BRAKES
TABLE OF CONTENTS
page
page
REMOVAL AND INSTALLATION
SPECIFICATIONS
REMOVAL AND INSTALLATION
BRAKE BOOSTER – RHD DIESEL
REMOVAL
(1) Open hood and disconnect the negative battery
cable
NOTE: Pump the brake pedal several times to
relieve vacuum in the brake booster. This will pre-
vent booster from sucking any contaminants when
master cylinder is removed.
(2) Remove the short brake lines leading from the
master cylinder to the combination valve (Fig. 1).
Fig. 2 Differential Pressure Switch Electrical
1 – SWITCH TERMINAL
2 – COMBINATION VALVE
3 – WIRE HARNESS CONNECTOR
(6) Disconnect the vacuum supply hose from the
brake booster.
(7) Disconnect the coolant level switch electrical
connector. Located on the side of the coolant reser-
voir.
Fig. 1 Brake Line Orientation
1 – COMBINATION VALVE
2 – MASTER CYLINDER
NOTE: It is not necessary to drain the cooling sys-
tem to perform this procedure.
(3) Disconnect differential pressure switch wire
from the combination valve. Lift the release tab on
the underside of the electrical connector and pull
straight off (Fig. 2).
(4) Remove the combination valve support bracket
retaining nuts and remove the valve and bracket
assembly from the vehicle.
(5) Remove the master cylinder retaining nuts
(Fig. 8) and remove the master cylinder from the
brake booster by sliding straight off mounting studs.
(8) Remove the coolant reservoir retaining screws
so reservoir can be positioned out of the way.
(9) Working inside the vehicle, remove the hood
release
cable
handle
retaining
screws
from
the
underside of the instrument panel.
(10) Remove the plastic and steel knee blockers
from the vehicle. Refer to Group 23, Body for the pro-
cedure.
 5 - 2
BRAKES
XJ
REMOVAL AND INSTALLATION (Continued)
Fig. 3 Master Cylinder
Fig. 5 Booster Mounting
1 – BOOSTER
1 – BOOSTER
2 – MASTER CYLINDER
NOTE: If a new master cylinder is being installed,
cylinder must be bench bleed prior to installation.
(11) Remove the retaining clip that secures the
booster push rod to the brake pedal (Fig. 4).
(1) Install the brake booster on the bulkhead, be
certain dash seal is installed on booster studs prior
to installation.
(2) From under the instrument panel, install
booster mounting nuts. Tighten nuts just enough to
hold booster in place.
NOTE: Lubricate the pedal pin and bushing with
Mopar multi-mileage grease before installation.
(3) Slide booster push rod onto the brake pedal
pin. Then secure push rod to pedal pin with retaining
clip.
(4) Torque booster mounting nuts to 39 N·m (29 ft.
lbs.).
(5) Install the steel and plastic knee blocker in the
vehicle. Refer to Group 23, Body for the procedure.
(6) Install the hood release cable handle.
(7) Install the coolant reservoir bottle retaining
screws and connect the coolant level switch.
(8) Connect the vacuum supply hose on the brake
booster.
(9) Install master cylinder on brake booster and
install retaining nuts. Torque the nuts to 17.5 N·m
(155 in. lbs.).
(10) Install combination valve/bracket and retain-
ing nuts.
(11) Install
Fig. 4 Booster Push Rod
1 – BRAKE PEDAL
2 – BOOSTER ROD
3 – BUSHING
(12) Remove nuts attaching booster to passenger
compartment side of dash panel (Fig. 5).
(13) Working inside the engine compartment, posi-
tion the coolant reservoir out of the way and remove
the brake booster by pulling straight out.
brake
lines
on
cylinder
and
valve.
INSTALLATION
Torque brake lines to 19 N·m (170 in. lbs.).
(12) Connect differential pressure switch wire on
the combination valve.
(13) Fill and bleed the brake system. Refer to the
procedure in this group.
(14) Connect the negative battery cable.
NOTE: Be
certain
rubber
o-ring
vacuum
seal
is
installed
in
the
master
cylinder
mounting
flange
prior to installation.
XJ
BRAKES
5 - 3
REMOVAL AND INSTALLATION (Continued)
(15) Adjust the brake lamp switch. Refer to the
procedure in this group.
WARNING: Be certain a firm brake pedal is
achieved prior to attempting to operate the vehicle.
MASTER CYLINDER – RHD DIESEL
REMOVAL
(1) Open hood and disconnect the negative battery
cable
NOTE: Pump the brake pedal several times to
relieve vacuum in the brake booster. This will pre-
vent booster from sucking any contaminants when
master cylinder is removed.
(2) Remove the short brake lines leading from the
master cylinder to the combination valve (Fig. 6).
Fig. 7 Differential Pressure Switch Electrical
1 – SWITCH TERMINAL
2 – COMBINATION VALVE
3 – WIRE HARNESS CONNECTOR
Fig. 6 Brake Line Orientation
1 – COMBINATION VALVE
2 – MASTER CYLINDER
(3) Disconnect differential pressure switch wire
from the combination valve. Lift the release tab on
the underside of the electrical connector and pull
straight off (Fig. 7).
(4) Remove the combination valve support bracket
retaining nuts and remove the valve and bracket
assembly from the vehicle.
(5) Remove the master cylinder retaining nuts
(Fig. 8) and remove the master cylinder from the
brake booster by sliding straight off mounting studs.
Fig. 8 Master Cylinder
1 – BOOSTER
2 – MASTER CYLINDER
NOTE: If a new master cylinder is being installed,
cylinder must be bench bleed prior to installation.
(1) If equipped, remove protective sleeve from pri-
mary piston shank on new master cylinder.
(2) Clean
INSTALLATION
cylinder
mounting
surface
of
brake
NOTE: Be
certain
rubber
o-ring
vacuum
seal
is
booster.
(3) Install master cylinder on brake booster and
install retaining nuts. Torque the nuts to 17.5 N·m
(155 in. lbs.).
installed
in
the
master
cylinder
mounting
flange
prior to installation.
 5 - 4
BRAKES
XJ
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
(4) Install combination valve/bracket and retaining
nuts.
(5) Install
brake
lines
on
cylinder
and
valve.
TORQUE SPECIFICATIONS
Torque brake lines to 19 N·m (170 in. lbs.).
(6) Connect differential pressure switch wire on
the combination valve.
(7) Fill and bleed the brake system. Refer to the
procedure in this group.
(8) Connect the negative battery cable.
(9) Adjust the brake lamp switch. Refer to the pro-
cedure in this group.
DESCRIPTION
TORQUE
Brake Booster to Cowl Panel
Nuts ..................... 39N·m(29ft.lbs.)
Brake Lines at Master Cylinder and
Combination Valve
Tube Nuts ................ 19N·m(170 in. lbs.)
Master Cylinder to Vacuum Booster
Nuts ................... 17.5 N·m (155 in. lbs.)
WARNING: Be certain a firm brake pedal is
achieved prior to attempting to operate the vehicle.
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