1995 JEEP CHEROKEE Service Repair Manual

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Page 177 of 2198

JEEP CHEROKEE 1995 Service Repair Manual CAUTION: The mercury switch (inside the accelera-
tion switch), will not function properly if the switch
is mispositioned. Verify that the switch locating ar-
row is pointing to the front of the vehic

Page 178 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (2) Align and attach harness connector to ECU.
Slide connector into engagement with tangs on ECU.
Then tilt connector downward and into engagement
with ECU pin terminals. Exercise care as pin termi-
n

Page 179 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (6) Disconnect both flex brakelines at HCU (Fig. 18).
(7) Disconnect HCU solenoid harness from main
harness (Fig. 19).
(8) Disconnect HCU pump motor harness (Fig. 20).(9) If HCU mounting bracket will

Page 180 of 2198

JEEP CHEROKEE 1995 Service Repair Manual HCU INSTALLATION (XJ)
(1) Install HCU as follows:
(a) If only the HCU was removed, position HCU
in mounting bracket. Then install and tighten
three shoulder bolts that attach HCU to bracket
(Figs. 23

Page 181 of 2198

JEEP CHEROKEE 1995 Service Repair Manual HCU REMOVAL (YJ)
(1) Place shop towels under master cylinder and
HCU brakelines.
(2) Disconnect flex lines at upper part of HCU.
(3) Disconnect solenoid and pump harness wires at
HCU harness connecter

Page 182 of 2198

JEEP CHEROKEE 1995 Service Repair Manual DISC BRAKES
INDEX
page page
Caliper Assembly......................... 50
Caliper Cleaning and Inspection.............. 50
Caliper Disassembly....................... 48
Caliper Installation............

DISC BRAKES
INDEX
page page
Caliper Assembly......................... 50
Caliper Cleaning and Inspection.............. 50
Caliper Disassembly....................... 48
Caliper Installation........................ 51
Caliper Operation and Wear Compensation...... 45
Caliper Removal.......................... 48
Disc Brake Rotor Refinishing................. 53
Disc Brake Rotor Runout.................... 52Disc Brake Rotor Thickness................. 52
Disc Brake Rotor Thickness Variation.......... 52
Disc Brakeshoe Installation.................. 47
Disc Brakeshoe Removal................... 46
General Information....................... 45
Rotor Installation.......................... 51
Rotor Removal........................... 51
Wheel Nut Tightening...................... 54
GENERAL INFORMATION
Jeep XJ/YJ models are equipped with single piston,
floating-type disc brake calipers. Ventilated, cast ro-
tors are used for all applications.
The disc brake calipers are supported in mounting
arms that are an integral part of the steering
knuckle. The calipers slide on mounting bolts that
also attach the calipers to the steering knuckle.
CALIPER OPERATION AND WEAR COMPENSATION
Caliper Operation
The significant feature of single piston caliper op-
eration is that the calipers are free to slide laterally
on the mounting bolts. It is the freedom of lateral
movement that allows continuous compensation for
lining wear.
A simplified cross section of a single piston caliper
is shown in Figure 1. The illustration graphically
portrays the forces at work when the brakes are ap-
plied.
Upon brake application, fluid pressure exerted
against the caliper piston increases greatly. Of equal
importance, is the fact that fluid pressure is exerted
equally and in all directions. What this means, is
that pressure in the caliper bore, will be exactly the
same as pressure on the piston. In other words, pres-
sure against piston and caliper bore is equal.
Fluid pressure applied to the piston is transmitted
directly to the inboard brakeshoe. This forces the
shoe lining against the inner surface of the disc
brake rotor (Fig. 1).
At the same time, fluid pressure within the piston
bore, forces the caliper to slide inward on the mount-
ing bolts. This action brings the outboard brakeshoe
lining into contact with the outer surface of the disc
brake rotor (Fig. 1).
In summary, fluid pressure acting simultaneously
on both piston and caliper, produces a strong clamp-
ing action. When sufficient force is applied, friction
will stop the rotors from turning and bring the vehi-
cle to a stop.Brakeshoe Wear Compensation
Application and release of the brake pedal gener-
ates only a very slight movement of the caliper and
piston. Upon release of the pedal, the caliper and pis-
ton return to a rest position. The brakeshoes do not
retract an appreciable distance from the rotor. In
fact, clearance is usually at, or close to zero. The rea-
sons for this are to keep road debris from getting be-
tween the rotor and lining and in wiping the rotor
surface clear each revolution.
The caliper piston seal controls the amount of pis-
ton extension needed to compensate for normal lining
wear.
During brake application, the seal is deflected out-
ward by fluid pressure and piston movement (Fig. 2).
When the brakes (and fluid pressure) are released,
the seal relaxes and retracts the piston.
Fig. 1 Disc Brake Caliper Operation
JDISC BRAKES 5 - 45

Page 183 of 2198

JEEP CHEROKEE 1995 Service Repair Manual The amount of piston retraction is determined by
brakelining wear. Generally, the amount is just
enough to maintain contact between the piston and
inboard brakeshoe. Brakelining running clearance at
t

Page 184 of 2198

JEEP CHEROKEE 1995 Service Repair 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

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