1995 JEEP XJ sensor

AXLE SPECIFICATIONS
MODEL 35 AXLE
Axle Type...............................Semi-Floating Hypoid
Lubricant................SAE Thermally Stable 80W-90
Lubricant Trailer Tow.............Synthetic 75W-140
Lube Capacity..............................1.66 L (3.50 pts.)
Axle Ratio................................3.07, 3.55, 3.73, 4.10
Differential
Bearing Preload ............................0.1 mm (0.004 in.)
Side Gear Clearance ............0-0.15 mm (0-0.006 in.)
Ring Gear
Diameter .......................................19.2 cm (7.562 in.)
Backlash.........................0-0.15 mm (0.005-0.008 in.)
Pinion Std. Depth...................96.8 mm (3.813 in.)
Pinion Bearing Preload
Original Bearing ....................1-2Nzm (10-20 in. lbs.)
New Bearing .......................1.5-4Nzm (15-35 in. lbs.)
8 1/4 AXLE
Axle Type................................Semi-floating, hypoid
Lubricant...............................................SAE 75W-90
Lube Capacity................................2.08 L (4.4 pts.)
Axle Ratios.........................................3.07 3.55 4.10
Differential
Side Gear Clearance ..................0.12 mm (0.005 in.)
Case Flange Runout ..................0.07 mm (0.003 in.)
Bearing Preload ...........................95 Nzm (70 ft. lbs.)
Ring Gear
Diameter .......................................20.95 cm (8.25 in.)
Backlash....................0.12-0.20 mm (0.005-0.008 in.)
Runout .......................................0.127 mm (0.005 in.)
Pinion Bearing
Preload ....................................1-2 Nzm (10-20 in.lbs.)
TORQUE SPECIFICATIONS
XJ REAR SUSPENSION COMPONENTS
DESCRIPTION ................................................TORQUE
Shock Absorber
Upper Bolt ...................................23 Nzm (17 ft. lbs.)
Lower Nut ....................................62 Nzm (46 ft. lbs.)
Stabilizer Bar
Clamp Bolt ...................................54 Nzm (40 ft. lbs.)
Link Upper Bolt ............................12 Nzm (9 ft. lbs.)
Link Lower Nut ..........................74 Nzm (55 ft. lbs.)
Spring
U-Bolt Nut ...................................70 Nzm (52 ft. lbs.)
Front Pivot Bolt ......................148 Nzm (109 ft. lbs.)
Upper Shackle Bolt .................148 Nzm (109 ft. lbs.)
Lower Shackle Bolt ...................108 Nzm (80 ft. lbs.)
YJ REAR SUSPENSION COMPONENTS
DESCRIPTION ................................................TORQUE
Shock Absorber
Upper Nut ....................................61 Nzm (45 ft. lbs.)
Lower Nut ....................................61 Nzm (45 ft. lbs.)
Track Bar
Frame Bracket Nut.................142 Nzm (105 ft. lbs.)
Axle Bracket Nut ....................142 Nzm (105 ft. lbs.)Spring
U-Bolt Nut .................................122 Nzm (90 ft. lbs.)
Rear Shackle Bolts..................136 Nzm (100 ft. lbs.)
Front Pivot Bolt ......................142 Nzm (105 ft. lbs.)
MODEL 35 AXLE
DESCRIPTION ................................................TORQUE
Fill Hole Plug...........................34 Nzm (25 ft. lbs.)
Diff. Cover Bolt........................41 Nzm (30 ft. lbs.)
Bearing Cap Bolt.....................77 Nzm (57 ft. lbs.)
Pinion Nut...............292-427 Nzm (215-315 ft. lbs.)
Ring Gear Bolt.............95-122 Nzm (70-90 ft. lbs.)
RWAL/ABS Sensor Bolt.........24 Nzm (18. ft. lbs.)
8 1/4 AXLE
DESCRIPTION ................................................TORQUE
Diff. Cover Bolt........................47 Nzm (35 ft. lbs.)
Bearing Cap Bolt.....................95 Nzm (70 ft. lbs.)
Pinion Nut.............................285 Nzm (210 ft. lbs.)
Ring Gear Bolt.........................95 Nzm (70 ft. lbs.)
RWAL/ABS Sensor Bolt.........24 Nzm (18. ft. lbs.)
JREAR SUSPENSION AND AXLES 3 - 51

ABS SYSTEM CHANGES
A different master cylinder, power brake booster,
and HCU are used in the 1995 Jeep ABS system.
The master cylinder reservoir has a single filler cap
and is no longer interconnected with the HCU. The
new HCU has built-in accumulators. The pedal travel
sensor has been eliminated and a new dual dia-
phragm power brake booster is used.
BRAKE FLUID/LUBRICANTS/CLEANING SOLVENTS
Recommended fluid for all Jeep vehicles is Mopar
DOT 3 brake fluid, or an equivalent meeting SAE
J1703 and DOT 3 standards.
Use Mopar Multi Mileage grease to lubricate drum
brake pivot pins and rear brakeshoe contact points
on the support plates. Use GE 661, or Dow 111 sili-
cone grease on caliper bushings and mounting bolts.
Use fresh brake fluid or Mopar brake cleaner to
clean or flush brake system components. These are
the only cleaning materials recommended.
CAUTION: Never use gasoline, kerosene, methyl or
isopropyl alcohol, paint thinner, or any fluid con-
taining mineral oil to clean brake parts. These fluids
damage rubber cups and seals. If system contami-
nation is suspected, check the fluid for dirt, discol-
oration, or separation into distinct layers. Drain and
flush the system with new brake fluid if contamina-
tion is suspected.
JEEP BODY CODE LETTERS
The body/model identification code letters for Jeep
vehicles are as follows:²Code letters XJ: Cherokee
²Code letters YJ: Wrangler/YJ
The code letters are used throughout this group to
simplify model identification and component applica-
tion.
BRAKE SAFETY PRECAUTIONS
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKELINING ON JEEP VEHICLES IS MADE FROM
ASBESTOS FREE MATERIALS, SOME AFTER MAR-
KET BRAKELINING MAY CONTAIN ASBESTOS. THIS
SHOULD BE TAKEN INTO ACCOUNT WHEN RE-
PAIRING A VEHICLE WITH PRIOR BRAKE SERVICE.
WEAR A RESPIRATOR WHEN CLEANING BRAKE
COMPONENTS AS ASBESTOS FIBERS CAN BE A
HEALTH HAZARD. NEVER CLEAN WHEEL BRAKE
COMPONENTS WITH COMPRESSED AIR. USE A
VACUUM CLEANER SPECIFICALLY DESIGNED FOR
REMOVING BRAKE DUST. IF A VACUUM CLEANER
IS NOT AVAILABLE, CLEAN THE PARTS WITH WA-
TER DAMPENED SHOP RAGS. DO NOT CREATE
DUST BY SANDING BRAKELINING. DISPOSE OF
ALL DUST AND DIRT SUSPECTED OF CONTAINING
ASBESTOS FIBERS IN SEALED BAGS OR CON-
TAINERS. FOLLOW ALL SAFETY PRACTICES REC-
OMMENDED BY THE OCCUPATIONAL SAFETY AND
HEALTH ADMINISTRATION (OSHA) AND THE ENVI-
RONMENTAL PROTECTION AGENCY (EPA), FOR
HANDLING AND DISPOSAL OF ASBESTOS.
5 - 2 BRAKESJ

ABS BRAKE DIAGNOSIS
INDEX
page page
ABS Diagnostic Connector................... 3
ABS Warning Light Display................... 3
Antilock ECU and Hcu Diagnosis............... 3
DRB Scan Tool............................ 3General Information........................ 3
Normal Operating Conditions.................. 3
Wheel/Tire Size and Input Signals.............. 3
GENERAL INFORMATION
The DRB scan tool is required for ABS diagnosis.
The scan tool is used to identify ABS circuit faults.
Once a faulty circuit has been identified, refer to
the appropriate chassis/body diagnostic manual for
individual component testing.
ABS WARNING LIGHT DISPLAY
The amber antilock light illuminates at startup as
part of the system self check feature. The light illu-
minates for 2-3 seconds then goes off as part of the
normal check routine.
An ABS circuit fault is indicated when the amber
light remains on after startup, or illuminates during
vehicle operation.
Verify that a fault is actually related to the ABS
system before making repairs. For example, if the
red warning illuminates but the ABS light does not,
the problem is related to a service brake component
and not the ABS system. Or, if neither light illumi-
nates but a brake problem is noted, again, the prob-
lem is with a service brake component and not with
the ABS system.
ABS DIAGNOSTIC CONNECTOR
The ABS diagnostic connector is inside the vehicle.
The connector is the access point for the DRB scan tool.
On XJ models, the connector is located under the
instrument panel to the right of the steering column.
On some models, the connecter may be tucked under
the carpeting on the transmission tunnel. The con-
necter is a black, 6-way type.
On YJ models, the connector is under the instru-
ment panel by the the driver side kick panel. The
connecter is a black, 6 or 8-way type.
The DRB scan tool kit contains adapter cords for
both types of connecter. Use the appropriate cord for
test hookup.
DRB SCAN TOOL
ABS diagnosis is performed with the DRB scan tool.
Refer to the DRB scan tool manual for test hookup and
procedures. Diagnosis information is provided in the ap-
propriate chassis/body diagnostic manual.
WHEEL/TIRE SIZE AND INPUT SIGNALS
Antilock system operation is dependant on accurate
signals from the wheel speed sensors. Ideally, the ve-
hicle wheels and tires should all be the same size
and type. However, the Jeep ABS system is designed
to operate with a compact spare tire installed.
NORMAL OPERATING CONDITIONS
Sound Levels
The hydraulic control unit pump and solenoid valves
may produce some sound as they cycle on and off. This
is a normal condition and should not be mistaken for
faulty operation. Under most conditions, pump and so-
lenoid valve operating sounds will not be audible.
Vehicle Response In Antilock Mode
During antilock braking, the hydraulic control unit
solenoid valves cycle rapidly in response to antilock
electronic control unit signals.
The driver will experience a pulsing sensation
within the vehicle as the solenoids decrease, hold, or
increase pressure as needed. Brake pedal pulsing will
also be noted and is anormal condition.
Steering Response
A modest amount of steering input is required dur-
ing extremely high deceleration braking, or when
braking on differing traction surfaces. An example of
differing traction surfaces would be when the left
side wheels are on ice and the right side wheels are
on dry pavement.
Owner Induced Faults
Driving away with the parking brakes still applied
will cause warning light illumination. Pumping the
brake pedal will also generate a system fault and in-
terfere with ABS system operation.
ANTILOCK ECU AND HCU DIAGNOSIS
An ECU or HCU fault can only be determined
through testing with the DRB scan tool. Do not re-
place either component unless a fault is actually in-
dicated.
JABS BRAKE DIAGNOSIS 5 - 3

connect scan tool and proceed to next step.
(7)Repeatconventional bleed procedure described
in steps (4) and (5).
(8) Top off master cylinder fluid level and verify
proper brake operation before moving vehicle.
BRAKELINES AND HOSES
Metal brakelines and rubber brake hoses should be
inspected periodically and replaced if damaged.
Rubber brake hoses should be replaced if cut,
cracked, swollen, or leaking. Rubber hoses must be
replaced as they are not repairable.
Steel brakelines should be inspected any time the
vehicle is in for normal maintenance. This is impor-
tant on high mileage vehicles. It is especially impor-
tant when the vehicle is operated on roads that are
salted during winter months.
Heavily rusted/corroded brake rotors, drums,
support plates, and brakelines should be
cleaned and carefully inspected. Heavy rust
buildup can hide severe damage to a compo-
nent. Severely rusted parts should be replaced
if condition is suspect.
BRAKELINE CHARTS
Brakeline routing and connections are displayed in
Figures 4 through 10. Routing for both right hand drive
(RHD) and left hand drive (LHD) models is provided.
Fig. 4 Brakeline Routing (YJ With ABS)
Fig. 5 Front Brake Hose And Sensor Wire Routing
(RHD XJ With ABS)
5 - 12 BRAKE FLUIDÐBRAKE BLEEDINGÐBRAKELINES AND HOSESJ

ABS OPERATION AND SERVICE
INDEX
page page
ABS Component Serviceability............... 37
ABS Diagnostic Connector.................. 35
ABS Operation in Antilock Braking Mode........ 36
ABS Operation in Normal Braking Mode........ 35
ABS System Power-Up and Initialization........ 35
Acceleration Switch........................ 35
Acceleration Switch Installation............... 39
Acceleration Switch Operation................ 37
Acceleration Switch Removal................ 39
Combination Valve........................ 34
ECU Installation (XJ Models)................. 40
ECU Operation........................... 37
ECU Removal (XJ Models).................. 40
ECU Removal/Installation (YJ Models).......... 41
Electronic Control Unit (ECU)................ 34
Front Wheel Sensor Installation............... 38
Front Wheel Sensor Removal................ 38HCU Installation (XJ)....................... 43
HCU Installation (YJ)....................... 44
HCU Operation........................... 36
HCU Removal (XJ)........................ 41
HCU Removal (YJ)........................ 44
Hydraulic Control Unit (HCU)................. 33
Ignition Switch........................... 35
Master Cylinder/Power Brake Booster.......... 34
Rear Wheel Sensor Installation and Adjustment . . . 38
Rear Wheel Sensor Removal................ 38
Speed Sensor Air Gap..................... 37
System Description........................ 33
System Relays........................... 35
System Warning Light...................... 35
Wheel Speed Sensor Operation.............. 37
Wheel Speed Sensors..................... 34
SYSTEM DESCRIPTION
The Jeep antilock brake system (ABS) is an elec-
tronically operated, all wheel brake control system.
The system is designed to prevent wheel lockup
and maintain steering control during periods of high
wheel slip when braking. Preventing lockup is accom-
plished by modulating fluid pressure to the wheel
brake units.
The hydraulic system is a three channel design.
The front wheel brakes are controlled individually
and the rear wheel brakes in tandem (Fig. 1). The
ABS electrical system is separate from other electri-
cal circuits in the vehicle. A specially programmed
electronic control unit (ECU) operates the system
components.
ABS system major components include:
²hydraulic control unit (HCU)
²electronic control unit (ECU)
²wheel speed sensors and axle shaft tone rings
²acceleration switch
²main relay and pump motor relay
²ABS warning light
²pump motor sensor
HYDRAULIC CONTROL UNIT (HCU)
The hydraulic control unit (HCU) consists of a
valve body, pump body, accumulators, pump motor,
and wire harnesses (Fig. 2).
The pump, motor, and accumulators are combined
into an assembly attached to the valve body. The ac-
cumulators store the extra fluid released to the sys-
tem for ABS mode operation. The pump provides the
fluid volume needed and is operated by a DC type
motor. The motor is controlled by the ECU.The valve body contains the solenoid valves. The
valves modulate brake pressure during antilock brak-
ing and are controlled by the ECU.
The HCU provides three channel pressure control
to the front and rear brakes. One channel controls
the rear wheel brakes in tandem. The two remaining
channels control the front wheel brakes individually.
During antilock braking, the solenoid valves are
opened and closed as needed. The valves are not static.
They are cycled rapidly and continuously to modulate
pressure and control wheel slip and deceleration.
Fig. 1 Jeep ABS System
JABS OPERATION AND SERVICE 5 - 33

MASTER CYLINDER/POWER BRAKE BOOSTER
A 25 mm bore master cylinder and 205 mm (8.07
in.) dual diaphragm power brake booster are used for
all ABS applications (Fig. 2).
The master cylinder has a removable plastic reser-
voir which is the only serviceable component. The
cylinder body and pistons are not repairable and are
serviced as an assembly. The check valve and grom-
met are the only serviceable parts on the booster.
The booster itself is only serviced as an assembly.
COMBINATION VALVE
A combination valve is used with the ABS system
(Fig. 2). The valve contains a front/rear brake pres-
sure differential switch and rear brake proportioning
valve. The combination valve is connected between
the master cylinder and HCU.
The pressure differential switch is connected to the
red brake warning light. The switch is actuated by
movement of the switch valve. The switch monitors
fluid pressure in the separate front/rear brake hy-
draulic circuits.
A decrease or loss of fluid pressure in either hy-
draulic circuit will cause the switch valve to shuttle
forward or rearward in response to the pressure dif-
ferential. Movement of the switch valve will push the
switch plunger upward. This closes the switch inter-
nal contacts completing the electrical circuit to the
red warning light. The switch valve remains in an
actuated position until the fault is repaired.
The rear proportioning valve is used to balance front-
rear brake action.
ELECTRONIC CONTROL UNIT (ECU)
A separate electronic control unit (ECU) operates
the ABS system (Fig. 3). The ECU is separate from
other vehicle electrical circuits. ECU voltage source
is through the ignition switch in the Run position.The ECU is located under the instrument panel in
the passenger compartment. On YJ models, it is just
above the heater plenum in line with the glove box.
In left hand drive XJ models, it at the right side of
the steering column. In right hand drive models, it is
near the cowl panel
The ECU contains dual microprocessors. A logic
block in each microprocessor receives identical sensor
signals. These signals are processed and compared si-
multaneously.
The ECU contains a self check program that illu-
minates the ABS warning light when a system fault
is detected. Faults are stored in a diagnostic program
memory and are accessible with the DRB scan tool.
ABS faults remain in memory until cleared, or un-
til after the vehicle is started approximately 50
times. Stored faults arenoterased if the battery is
disconnected.
WHEEL SPEED SENSORS
A speed sensor is used at each wheel. The sensors
convert wheel speed into an electrical signal. This
signal is transmitted to the antilock ECU.
A gear type tone ring serves as the trigger mecha-
nism for each sensor. The tone rings are mounted at
the outboard ends of the front and rear axle shafts.
Different sensors are used at the front and rear
wheels (Fig. 4). The front/rear sensors have the same
electrical values but are not interchangeable.
Fig. 2 ABS Master Cylinder-Booster-Combination
Valve-HCU
Fig. 3 Antilock ECU
5 - 34 ABS OPERATION AND SERVICEJ

ABS DIAGNOSTIC CONNECTOR
The ABS diagnostic connector is inside the vehicle.
The connector is the access point for the DRB scan
tool.
On XJ models, the connector is located under the
instrument panel to the right of the steering column.
On some models, the connecter may be tucked under
the carpeting on the transmission tunnel. The con-
necter is a black, 6-way type.
On YJ models, the connector is under the instru-
ment panel by the the driver side kick panel. The
connecter is a black, 6 or 8-way type.
The DRB scan tool kit contains adapter cords for
both types of connecter. Use the appropriate cord for
test hookup.
ACCELERATION SWITCH
An acceleration switch (Fig. 5), provides an addi-
tional vehicle deceleration reference during 4-wheel
drive operation. The switch is monitored by the an-
tilock ECU at all times. The switch reference signal
is utilized by the ECU when all wheels are deceler-
ating at the same speed.
SYSTEM RELAYS
The ABS system has two relays, which are the
main and motor pump relays. The motor pump relay
is used for the motor pump only. The main relay is
used for the solenoid valves and ECU. The main re-
lay is connected to the ECU at the power control re-
lay terminal. The pump motor relay starts/stops the
pump motor when signaled by the ECU.
IGNITION SWITCH
The antilock ECU and warning light are in standby
mode with the ignition switch in Off or Accessory po-
sition. No operating voltage is supplied to the system
components.A 12 volt power feed is supplied to the ECU and
warning light when the ignition switch is in the Run
position.
SYSTEM WARNING LIGHT
The amber ABS warning light is in circuit with the
ECU and operates independently of the red brake
warning light.
The ABS light indicates antilock system condition.
The light illuminates (flashes) at start-up for the self
check. The light goes out when the self check pro-
gram determines system operation is normal.
ABS SYSTEM POWER-UP AND INITIALIZATION
battery voltage is supplied to the ECU ignition ter-
minal when the ignition switch is turned to Run po-
sition. The ECU performs a system initialization
procedure at this point. Initialization consists of a
static and dynamic self check of system electrical
components.
The static check occurs after the ignition switch is
turned to Run position. The dynamic check occurs
when vehicle road speed reaches approximately 10
kph (6 mph). During the dynamic check, the ECU
briefly cycles the pump and solenoids to verify oper-
ation.
If an ABS component exhibits a fault during initial-
ization, the ECU illuminates the amber warning
light and registers a fault code in the microprocessor
memory.
ABS OPERATION IN NORMAL BRAKING MODE
The ECU monitors wheel speed sensor inputs con-
tinuously while the vehicle is in motion. However,
the ECU will not activate any ABS components as
long as sensor inputs and the acceleration switch in-
dicate normal braking.
Fig. 4 Wheel Speed SensorsFig. 5 Acceleration Switch
JABS OPERATION AND SERVICE 5 - 35

During normal braking, the master cylinder, power
booster and wheel brake units all function as they
would in a vehicle without ABS. The HCU compo-
nents are not activated.
ABS OPERATION IN ANTILOCK BRAKING MODE
The purpose of the antilock system is to prevent
wheel lockup during periods of high wheel slip. Pre-
venting lockup helps maintain vehicle braking action
and steering control.
The antilock ECU activates the system whenever
sensor signals indicate periods of high wheel slip.
High wheel slip can be described as the point where
wheel rotation begins approaching zero (or lockup)
during braking. Periods of high wheel slip may occur
when brake stops involve high pedal pressure and
rate of deceleration.
The antilock system prevents lockup during high
slip conditions by modulating fluid apply pressure to
the wheel brake units.
Brake fluid apply pressure is modulated according
to wheel speed, degree of slip and rate of decelera-
tion. A sensor at each wheel converts wheel speed
into electrical signals. These signals are transmitted
to the ECU for processing and determination of
wheel slip and deceleration rate.
The ABS system has three fluid pressure control
channels. The front brakes are controlled separately
and the rear brakes in tandem (Fig. 1). A speed sen-
sor input signal indicating a high slip condition acti-
vates the ECU antilock program.
Two solenoid valves are used in each antilock con-
trol channel. The valves are all located within the
HCU valve body and work in pairs to either increase,
hold, or decrease apply pressure as needed in the in-
dividual control channels.
The solenoid valves are not static during antilock
braking. They are cycled continuously to modulate
pressure. Solenoid cycle time in antilock mode can be
measured in milliseconds.
HCU OPERATION
Normal Braking
During normal braking, the HCU solenoid valves
and pump are not activated. The master cylinder and
power booster operate the same as a vehicle without
an ABS brake system.
Antilock Pressure Modulation
Solenoid valve pressure modulation occurs in three
stages which are: pressure increase, pressure hold,
and pressure decrease. The valves are all contained
in the valve body portion of the HCU.
Pressure Decrease
The outlet valve is opened and the inlet valve is
closed during the pressure decrease cycle (Fig. 6).A pressure decrease cycle is initiated when speed
sensor signals indicate high wheel slip at one or
more wheels. At this point, the ECU opens the outlet
valve, which also opens the return circuit to the ac-
cumulators. Fluid pressure is allowed to bleed off (de-
crease) as needed to prevent wheel lock.
Once the period of high wheel slip has ended, the
ECU closes the outlet valve and begins a pressure in-
crease or hold cycle as needed.
Pressure Hold
Both solenoid valves are closed in the pressure hold
cycle (Fig. 7). Fluid apply pressure in the control
channel is maintained at a constant rate. The ECU
maintains the hold cycle until sensor inputs indicate
a pressure change is necessary.
Pressure Increase
The inlet valve is open and the outlet valve is
closed during the pressure increase cycle (Fig. 8). The
pressure increase cycle is used to counteract unequal
wheel speeds. This cycle controls re-application of
fluid apply pressure due to changing road surfaces or
wheel speed.
Fig. 6 Pressure Decrease Cycle
5 - 36 ABS OPERATION AND SERVICEJ