2002 JEEP GRAND CHEROKEE 23 body

SPECIAL TOOLS
REAR SUSPENSION
LOWER CONTROL ARM
DESCRIPTION
The lower suspension arms are hydroformed steel
and use voided oval bushings at each end of the arm.
OPERATION
The bushings provide isolation from the axle. The
arms mount to the unibody frame rail bracket and
the axle brackets. The arm and bushings provide
location and react to loads.
REMOVAL
(1) Raise the vehicle and support the rear axle.
(2) Remove the lower suspension arm nut and bolt
from the axle bracket (Fig. 2).
(3) Remove the nut and bolt (Fig. 2) from the
frame rail and remove the lower suspension arm.
INSTALLATION
(1) Position the lower suspension arm in the axle
bracket and frame rail bracket.
NOTE: The end of the arm with the oval bushing
attaches to the axle bracket.
(2) Install the axle bracket bolt and nut finger
tight.
(3) Install the frame rail bracket bolt and nut fin-
ger tight.
(4) Remove the supports and lower the vehicle.
(5) With the vehicle on the ground tighten the nut
at the frame to 156 N´m (115 ft. lbs.). Tighten the
nut at the axle bracket to 163 N´m (120 ft. lbs.).
SHOCK
DESCRIPTION
The top of the shock absorbers are bolted to the
body. The bottom of the shocks are bolted to the axle
brackets. The standard shocks have conventional
twin tube construction and are low pressure gas
charged. Gas charging prevents cavitation during
rough road operation. Up-Country shocks are mono
tube design and are high pressure gas charged.
OPERATION
The shock absorbers dampen jounce and rebound
motion of the vehicle over various road conditions
and limit suspension rebound travel.
REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support the axle.
CAUTION: Do not allow the axle to hang from the
upper suspension arm ball joint.
(2) Remove the upper nut and bolt from the frame
bracket (Fig. 3).
(3) Remove the lower nut and bolt from the axle
bracket. Remove the shock absorber.
INSTALLATION
(1) Install the shock absorber in the frame bracket
and install the bolt and nut.
(2) Install the shock absorber in the axle bracket
and install the bolt and nut.
(3) Tighten the upper mounting nuts to 108 N´m
(80 ft. lbs.). Tighten the lower mounting nuts to 115
N´m (85 ft. lbs.).
(4) Remove the supports and lower the vehicle.
Remover 8278
Fig. 2 Lower Suspension Arm
1 - LOWER SUSPENSION ARM
2 - AXLE BRACKET
3 - FRAME BRACKET
WJREAR 2 - 19
REAR (Continued)

SPRING
DESCRIPTION
The coil springs mount up in the wheelhouse which
is part of the unitized body bracket. A rubber dough-
nut isolator is located between the top of the spring
and the body. The bottom of the spring seats on a
axle isolator made of rubber with a steel insert. The
isolators provide road noise isolation
OPERATION
The coil springs control ride quality and maintain
proper ride height.
REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support the axle.
(2) Remove the wheel and tire assemblies.
(3) Remove the stabilizer bar link from the stabi-
lizer bar (Fig. 4).
(4) Remove the shock absorber lower bolt from the
axle bracket.
(5) Lower the hydraulic jack and tilt the axle and
remove the coil spring (Fig. 4).
(6) Remove and inspect the upper and lower
spring isolators (Fig. 4).
INSTALLATION
(1) Install the upper isolator.
(2) Install the lower isolator with the isolator loca-
tor nub in the axle pad hole (Fig. 5).
(3) Pull down on the axle and position the coil
spring in the lower isolator.CAUTION: Ensure the spring is positioned on the
lower isolator with the end of the spring coil
against the isolator spring locator (Fig. 6).
(4) Raise the axle with the hydraulic jack.
(5) Install the shock absorber to the axle bracket
and tighten to specification.
(6) Install the stabilizer bar link to the stabilizer
bar.
(7) Install the wheel and tire assemblies.
(8) Remove the supports and lower the vehicle.
(9) Tighten the stabilizer bar links to specification.
Fig. 3 Shock Absorber
1 - SHOCKFig. 4 Coil Spring
1 - COIL SPRING
2 - ISOLATOR
3 - STABILIZER LINK
4 - ISOLATOR
Fig. 5 Isolator Locator Nub
1 - LOWER ISOLATOR
2 - LOCATOR NUB
3 - AXLE SPRING PAD
2 - 20 REARWJ
SHOCK (Continued)

STABILIZER BAR
DESCRIPTION
The stabilizer bar extends across the back side of
the rear axle. Links are connected between the bar
and frame rail brackets. The stabilizer bar and links
are isolated by rubber bushings.
OPERATION
The stabilizer bar is used to control vehicle body
roll, during turns. The bar helps control the vehicle
body in relationship to the suspension.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the stabilizer bar links from stabilizer
bar and frame mount. (Fig. 7).
(3) Remove the stabilizer bar retainer bolts.
(4) Remove the stabilizer bar.
INSTALLATION
(1) Position the stabilizer bar on the axle and
install the retainers and bolts. Ensure the bar is cen-
tered with equal spacing on both sides. Tighten the
bolts to 54 N´m (40 ft. lbs.).
(2) Install the links to the stabilizer bar and frame
brackets.
(3) Tighten the nuts at the stabilizer bar to 54
N´m (40 ft. lbs.).
(4) Tighten the nuts at the frame brackets to 92
N´m (68 ft. lbs.).
(5) Remove support and lower the vehicle.
UPPER BALL JOINT
DESCRIPTION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT
The suspension arm uses vertical spool bushings to
isolate road noise. The suspension arm is bolted
through bushings to cage nuts in the body and a ball
joint plate to the top of the differential housing.
OPERATION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT
The upper suspension arm provides fore/aft and
lateral location of the rear axle. The suspension arm
travel is limited through the use of jounce bumpers
in compression and shock absorbers in rebound.
REMOVAL
(1) Raise and support the vehicle.
(2) Support the rear axle with a hydraulic jack.
(3) Remove the ball joint nut from the top of the
upper suspension arm (Fig. 8).
(4) Separate ball joint from the arm with Remover
8278 (Fig. 9).
NOTE: It may be necessary to strike the upper con-
trol arm with a hammer to separate the ball joint
from the arm.
(5) Remove the ball joint mounting bolts (Fig.
10)from the differential housing.
(6) Remove the ball joint from the differential
housing.
Fig. 6 Isolator Spring Locator - Typical
1 - LOWER ISOLATOR
2 - SPRING LOCATOR
3 - COIL SPRING
Fig. 7 Rear Stabilizer Bar
1 - LINK
2 - RETAINER
3 - BUSHING
4 - STABILIZER BAR
WJREAR 2 - 21
SPRING (Continued)

INSTALLATION
(1) Install the ball joint on the differential hous-
ing.
(2) Install the ball joint mounting bolts and
tighten to 136 N´m (100 ft. lbs.).
(3) Raise the rear axle with a hydraulic jack to
align the upper arm with the ball joint.(4) Pull the arm down on the ball joint stud and
install anewnut. Tighten the nut to 142 N´m (105
ft. lbs.).
(5) Remove the supports and lower the vehicle.
UPPER CONTROL ARM
DESCRIPTION
The suspension arm uses vertical spool bushings to
isolate road noise. The suspension arm is bolted
through bushings to cage nuts in the body and a ball
joint plate to the top of the differential housing.
OPERATION
The upper suspension arm provides fore/aft and
lateral location of the rear axle. The suspension arm
travel is limited through the use of jounce bumpers
in compression and shock absorbers in rebound.
REMOVAL
(1) Raise and support the vehicle.
(2) Support the rear axle with a hydraulic jack.
(3) Remove the park brake cables and brake hose
from the arm (Fig. 11).
(4) Remove the ball joint nut from the top of the
upper suspension arm (Fig. 12).
(5) Separate ball joint from the arm with Remover
8278 (Fig. 13).
Fig. 8 Ball Joint Nut
1 - BALL JOINT NUT
2 - UPPER SUSPENSION ARM
Fig. 9 Separate Ball Joint
1 - REMOVER
2 - UPPER SUSPENSION ARM
3 - BALL JOINT STUD
Fig. 10 Ball Joint Mounting Bolts
1 - BALL JOINT
2 - MOUNTING BOLTS
2 - 22 REARWJ
UPPER BALL JOINT (Continued)

PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring gear and pinion are serviced as a
matched set. Nevar replace one gear without replac-
ing the other matching gear.
(1) Raise and support vehicle
(2) Mark pinion companion flange and propeller
shaft for installation alignment.
(3) Remove propeller shaft from pinion companion
flange and tie propeller shaft to underbody.
(4) Remove differential from axle housing.
(5) Place differential case in a vise with soft metal
jaw (Fig. 51).
(6) Remove bolts holding ring gear to differential
case.
NOTE: On Veri-LokTdifferential the side bearing
and oil feed plenum must be removed before
removing the ring gear bolts.
(7) Driver ring gear off the differential case with a
rawhide hammer (Fig. 51).(8) With Spanner Wrench 6958 and a short length
of 1 in. pipe, hold pinion companion flange and
remove pinion nut and washer (Fig. 52).
(9) Remove pinion companion flange from pinion
shaft with Remover C-452 and Flange Wrench
C-3281.
Fig. 50 DIFFERENTIAL CASE BEARING
1 - INSTALLER
2 - HANDLE
Fig. 51 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 52 Pinion Flange
1 - PINION FLANGE
2 - FRONT AXLE
3 - SPANNER WRENCH
WJFRONT AXLE - 186FBI 3 - 45
DIFFERENTIAL CASE BEARINGS (Continued)

INSTALLATION
NOTE: If differential side bearings or differential
case are replaced, differential side bearing shim
requirements may change. Refer to Adjustments
(Differential Bearing Preload and Gear Backlash) for
procedures.
(1) Install differential side bearings with Installer
C-3716-A and Handle C-4171 (Fig. 70).
(2) Install differential in axle housing.
(3) Remove support and lower vehicle.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are serviced as a
matched set. Never replace one gear without the
other gear.
(1) Raise and support vehicle.
(2) Mark pinion yoke and propeller shaft for
installation reference.
(3) Disconnect propeller shaft from pinion yoke
and tie shaft to underbody.
(4) Remove differential from the housing.
(5) Place differential case in a vise with soft metal
jaw.(6) Remove bolts holding ring gear to differential
case.
(7) Drive ring gear from differential case with a
rawhide hammer (Fig. 71).
(8) Hold the pinion yoke with Spanner Wrench
6958 and remove the pinion yoke nut and washer
(Fig. 72).
Fig. 70 Differential Side Bearing
1 - INSTALLER
2 - HANDLE
Fig. 71 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 72 PINION YOKE HOLDER
1 - 1 in. PIPE
2 - PINION YOKE
3 - HOLDER
4 - LOWER CONTROL ARM
3 - 84 REAR AXLE - 198RBIWJ
DIFFERENTIAL CASE BEARINGS (Continued)

CAUTION: Vari-lokTplenum must be seated against
the differential case prior to installing the ring gear
side differential bearing.
(1) Install differential side bearings with Installer
C-4340 and Handle C-4171 (Fig. 70).
(2) Install differential case into the housing.
(3) Remove support and lower vehicle.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are serviced as a
matched set. Never replace one gear without the
other matched gear.
(1) Raise and support vehicle.
(2) Mark pinion yoke and propeller shaft for
installation reference.
(3) Disconnect propeller shaft from pinion yoke
and tie shaft to underbody.
(4) Remove differential from axle housing.
(5) Place differential case in a vise with soft metal
jaw.
(6) Remove bolts holding ring gear to differential
case.(7) Drive ring gear from differential case with a
rawhide hammer (Fig. 71).
(8) Hold the pinion yoke with Spanner Wrench
6958 and remove the pinion yoke nut and washer
(Fig. 72).
Fig. 70 Install Differential Side Bearings
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 71 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 72 Pinion Yoke Holder
1 - PIPE
2 - PINION YOKE
3 - SPANNER WRENCH
4 - LOWER CONTROL ARM
3 - 124 REAR AXLE - 226RBAWJ
DIFFERENTIAL CASE BEARINGS (Continued)

INSTALLATION.........................23
MASTER CYLINDER
DESCRIPTION.........................23
OPERATION...........................24
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER...........24
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING PROCEDURE......25
REMOVAL.............................25
INSTALLATION.........................25
PEDAL
DESCRIPTION
DESCRIPTION - STANDARD PEDAL.......25
DESCRIPTION - ADJUSTABLE PEDALS....25
OPERATION...........................26
REMOVAL
REMOVAL - NON-ADJUSTABLE PEDAL....26
REMOVAL - ADJUSTABLE PEDALS........27
INSTALLATION
INSTALLATION - NON-ADJUSTABLE PEDAL . 28
INSTALLATION - ADJUSTABLE PEDALS....28
PEDAL MOTOR
REMOVAL.............................28
INSTALLATION.........................28
POWER BRAKE BOOSTER
DESCRIPTION.........................29
OPERATION...........................29
REMOVAL.............................31
INSTALLATION.........................31
ROTORS
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FRONT DISC
BRAKE ROTOR.......................31DIAGNOSIS AND TESTING - REAR DISC
BRAKE ROTOR.......................32
STANDARD PROCEDURE - DISC ROTOR
MACHINING..........................33
REMOVAL
REMOVAL - FRONT DISC BRAKE ROTOR . . 33
REMOVAL - REAR DISC BRAKE ROTOR . . . 33
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
ROTOR .............................34
INSTALLATION - REAR DISC BRAKE
ROTOR .............................34
PARKING BRAKE
OPERATION...........................34
DIAGNOSIS AND TESTING - PARKING BRAKE . 34
CABLES
REMOVAL
REMOVAL - FRONT PARKING BRAKE
CABLE..............................35
REMOVAL - REAR PARKING BRAKE
CABLES............................36
INSTALLATION
INSTALLATION - FRONT PARKING BRAKE
CABLE..............................37
INSTALLATION - REAR PARKING BRAKE
CABLES............................37
LEVER
REMOVAL.............................38
INSTALLATION.........................39
SHOES
REMOVAL.............................39
INSTALLATION.........................39
ADJUSTMENTS - PARKING BRAKE SHOE....40
BRAKES - BASE
DESCRIPTION
Dual piston disc brake calipers are used on the
front. Single piston disc brake calipers are used on
the rear. Ventilated disc brake rotors are used on the
front and solid rotors are used on the rear.
Power brake assist is supplied by a vacuum oper-
ated, dual diaphragm power brake booster. The mas-
ter cylinder used for all applications has an
aluminum body and nylon reservoir with single filler
cap. A fluid level indicator is mounted to the side of
the reservoir.
The braking force of the rear wheels is controlled
by electronic brake distribution (EBD). The EBD
functions like a rear proportioning valve. The EBD
system uses the ABS system to control the slip of the
rear wheels in partial braking range. The braking
force of the rear wheels is controlled electronically by
using the inlet and outlet valves located in the HCU.
Factory installed brake linings on all models con-
sists of organic base material combined with metallic
particles.
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
Base brake components consist of the brake shoes,
calipers, rear park brake drums/rotors, front brake
rotors, brake lines, master cylinder, booster, HCU
and parking brake shoes.
Brake diagnosis involves determining if the prob-
lem is related to a mechanical, hydraulic, electrical
or vacuum operated component.
The first diagnosis step is the preliminary check.
PRELIMINARY BRAKE CHECK
(1) Check condition of tires and wheels. Damaged
wheels and worn, damaged, or underinflated tires
can cause pull, shudder, vibration, and a condition
similar to grab.
5 - 2 BRAKES - BASEWJ